Still RXE 10 Original Instructions Manual
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Still RXE 10 Original Instructions Manual

Electric truck
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Original instructions
Electric truck
RXE 10-16C
5510 5513 5515 5516
55048015301 EN - 12/2023  -  07

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Summary of Contents for Still RXE 10

  • Page 1 Original instructions Electric truck RXE 10-16C 5510 5513 5515 5516 55048015301 EN - 12/2023  -  07...
  • Page 3 ● ing and storage of industrial trucks Internet address and QR code  The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 55048015301 EN - 12/2023  -  07  I...
  • Page 4  You can request to download the spare parts list by copying and pasting the address https:// sparepartlist.still.eu into a web browser or by scanning the QR code shown to the side. On the web page, enter the following pass-...

  • Page 5: Table Of Contents

    Table of contents   Foreword   Your truck ............ 2 Description of the truck .
  • Page 6 Operating devices and display elements ........ 64 Display-operating unit "STILL Easy Control" ........ 64 Emergency off switch .
  • Page 7 Table of contents   Operation   Checks and tasks before daily use ........ 78 Visual inspections and function checking .
  • Page 8 STILL Classic and sprint mode ........
  • Page 9 Table of contents   Operating devices for the lifting system........ 179 Controlling the lifting system using multi-lever operation .
  • Page 10 Table of contents   Automatic mast vertical positioning (variant) ........ 250 Function checking of the automatic mast vertical positioning function (variant) .
  • Page 11 Table of contents   Controlling attachments using the triple mini-lever and the 5th function ... . .  307 Controlling attachments using a quadruple mini-lever...... 309 Controlling attachments using the quadruple mini-lever and the 5th function .
  • Page 12 Table of contents   Equalising charging to preserve the battery capacity ...... 371 Battery maintenance indicator for lead-acid batteries (variant) .... 373 Handling the gel battery.
  • Page 13 Table of contents   Safety devices ............ 419 Set values .
  • Page 14 Table of contents   Battery specifications for lithium-ion batteries .......  461 Eco-design requirements for electric motors and variable speed drives .

  • Page 15: Foreword

    Foreword...

  • Page 16: Your Truck

    Assistance systems The STILL RXE can be equipped with assis- tance systems that make it easier to work with loads. Lift height-dependent assistance systems Lift height display ●...
  • Page 17 Foreword Your truck Load-dependant assistance systems Overload detection ● Dynamic Load Control 1 or Dynamic Load ● Control 2 Lift mast tilt angle display ● Automatic mast vertical positioning ● Fork wear protection ● Load measurement, precise load measure- ● ment, total load and tare function Brake system The brake system of the truck comprises three different brakes:...
  • Page 18 Foreword Your truck Drive The RXE 10-16 is driven via the rear wheel by a maintenance-free three-phase drive with 24-volt technology. Lead-acid batteries and lithium-ion batteries are available as an energy supply source. With the Li-Ion ready variant, the truck can be prepared ex works for the later use of a lithium-ion battery.

  • Page 19: General

    Foreword Your truck dividually selected from three different driving programmes. The "STILL Easy Control" display-operating unit simplifies daily use of the truck by pro- viding personally configurable favourites. The display-operating unit also shows the status of the lithium-ion battery. General The truck described in these operating instruc- tions corresponds to the applicable standards and safety regulations.

  • Page 20: Conformity Marking

    Foreword Your truck Conformity marking  The manufacturer uses the conformity mark- ing to document the conformity of the industri- al truck with the relevant directives at the time of placing on the market: CE: in the European Union (EU) ●...

  • Page 21: Declaration That Reflects The Content Of The Declaration Of Conformity

    Your truck Declaration that reflects the content of the declaration of conformity         Declaration     STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany             We declare that the specified machine conforms to the most recent valid version of the directives specified below:  ...

  • Page 22: Accessories

    Foreword Your truck Accessories Key for key switch (two pieces) ● Hexagon socket wrench for emergency low- ● ering  8 55048015301 EN - 12/2023  -  07...
  • Page 23 Foreword Your truck 55048015301 EN - 12/2023  -  07  9...

  • Page 24: Labelling Points

    Foreword Your truck Labelling points 0009386475 9K18 5F11 5F13 5F15 5F14 1K4-B 1K4-A 55044391310 55044391309 5510_003-001_V3  10 55048015301 EN - 12/2023  -  07...

  • Page 25: Nameplate

    Foreword Your truck Decal information: Caution/read the operat- Decal information: Caution / Read the oper- ing instructions ating instructions / Fasten seat belt / Apply Decal information: Speed reduction parking brake when leaving the truck / Pas- Warning sign: Danger due to shearing sengers are not allowed / Do not jump off if Decal information: Actions to be performed the truck is tipping over / Lean in the oppo-...

  • Page 26: Serial Number

    Foreword Your truck Variant 2: Industrial trucks built after  12/2021 Nameplate Manufacturer Model / serial number / year of manufac- ture Industrial truck / Chariot de manutation / Flurförderzeug Tare weight Max. battery weight/min. battery weight (only for electric trucks) Ballast weight (only for electric trucks) Placeholder for "data matrix code"...

  • Page 27: Stvzo (Road Traffic Licensing Regulations) Information

    Foreword Your truck StVZO (Road Traffic Licensing  Regulations) information This label includes information on the weight and load distribution of the truck. 7094_003-098_V2 Tare weight (in kg) Permitted total weight (in kg) Permitted front axle weight (in kg) Permitted rear axle weight (in kg) Payload (in kg) 55048015301 EN - 12/2023  - ...

  • Page 28: Using The Truck

    Foreword Using the truck Using the truck Commissioning Commissioning is the initial intended use of the truck. The necessary steps for the commissioning vary depending on the model and equipment of the truck. These steps require preparatory work and adjustment work that cannot be per- formed by the operating company.

  • Page 29: Place Of Use

    Foreword Using the truck Use for purposes other than those described in these operating instructions is prohibited.  DANGER There is a risk of fatal injury from falling off the truck while it is moving! – It is prohibited to carry passengers on the truck.

  • Page 30: Parking In Temperatures Below -10 °C

    Foreword Using the truck  CAUTION Batteries may freeze! If the truck is parked in an ambient temperature of below -10 °C for an extended period, the batteries will cool down. The electrolyte may freeze and dam- age the batteries. The truck will then not be ready for operation.

  • Page 31: Using Working Platforms

    Foreword Using the truck Using working platforms  WARNING The use of working platforms is regulated by national law. The use of working platforms is only permitted by virtue of the jurisdiction in the country of use. – Observe national legislation. –...

  • Page 32: Information About The Documentation

    Foreword Information about the documentation Information about the documentation Scope of the documentation Original operating instructions of the truck ● Original operating instructions of the dis- ● play-operating unit Original operating instructions of the lithium- ● ion battery (variant) Operating instructions of other variants that ●...

  • Page 33: Supplementary Documentation

    Foreword Information about the documentation Safely store the complete documentation and pass on to the subsequent operating company when transferring or selling the truck. NOTE Please note the definition of the following re- sponsible persons: "operating company" and "driver". Thank you for reading and complying with these operating instructions.

  • Page 34: Issue Date And Topicality Of The Operating Instructions

    The issue date and the version of these op- erating instructions can be found on the title page. STILL is constantly engaged in the further de- velopment of trucks. These operating instruc- tions are subject to change, and any claims based on the information and/or illustrations contained in them cannot be asserted.

  • Page 35: Explanation Of Signal Terms Used

    Foreword Information about the documentation Explanation of signal terms used  DANGER Indicates procedures that must be strictly adhered to in order to prevent the risk of fatalities.  WARNING Indicates procedures that must be strictly adhered to in order to prevent the risk of injuries.  CAUTION Indicates procedures that must be strictly adhered to in order to prevent material damage and/or destruc-...
  • Page 36 Foreword Information about the documentation Abbrevi- Meaning Explanation ation Confirms conformity with product-specific Communauté Européenne European directives (CE labelling) Commission on the Rules for the Approval International commission on the rules for of the Electrical Equipment the approval of electrical equipment Direct Current Direct current DFÜ...

  • Page 37: Definition Of Directions

    Foreword Information about the documentation Abbrevi- Meaning Explanation ation Tyres for simplified assembly, without Snap-In Tyre loose rim parts German regulations for approval of vehi- StVZO Straßenverkehrs-Zulassungs-Ordnung cles on public roads Ordinance on hazardous materials appli- TRGS Technische Regel für Gefahrstoffe cable in the Federal Republic of Germany Confirms conformity with the product-spe- UKCA...

  • Page 38: Schematic Views

    Foreword Information about the documentation Schematic views View of functions and operating proce-  dures At many points in this documentation, the (mostly sequential) operation of certain func- tions or operating procedures is explained. Schematic diagrams of a counterbalance truck are used to illustrate these procedures.

  • Page 39: Environmental Considerations

    Foreword Environmental considerations Environmental considerations Packaging During delivery of the truck, certain parts are packaged to provide protection during trans- port. This packaging must be removed com- pletely prior to initial start-up. ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck.
  • Page 40 Foreword Environmental considerations  26 55048015301 EN - 12/2023  -  07...

  • Page 41: Safety

    Safety...

  • Page 42: Definition Of Responsible Persons

    Safety Definition of responsible persons Definition of responsible persons Operating company The operating company is the natural or legal person or group who operates the truck or on whose authority the truck is used. The operating company must ensure that the truck is only used for its proper purpose and in compliance with the safety regulations set out in these operating instructions.

  • Page 43: Drivers

    Safety Definition of responsible persons Drivers This truck may only be driven by suitable per- sons who are at least 18 years of age, have been trained in driving, have demonstrated their skills in driving and handling loads to the operating company or an authorised represen- tative, and have been specifically instructed to drive the truck.
  • Page 44 Safety Definition of responsible persons Prohibition of use by unauthorised per- sons The driver is responsible for the truck during working hours. He must not allow unauthor- ised persons to operate the truck. When leaving the truck, the driver must secure it against unauthorised use, e.g.

  • Page 45: Basic Principles For Safe Operation

    Safety Basic principles for safe operation Basic principles for safe operation Insurance cover on company premises In many cases, company premises are restric- ted public traffic areas. NOTE The business liability insurance should be re- viewed to ensure that, in the event of any damage caused in restricted public traffic areas, there is insurance cover for the truck in respect of third parties.
  • Page 46 Safety Basic principles for safe operation Only the authorised service centre is permitted to perform welding work on the truck.  DANGER Risk of explosion from additional bores in the battery hood! Explosive gases can escape and can lead to potentially fatal injuries if they explode.

  • Page 47: Changes To The Overhead Guard And Roof Loads

    Safety Basic principles for safe operation they are consistent with the modifications and must be amended if required. Modifications must be designed, checked ● and implemented by a design office that specialises in industrial trucks. The design office must comply with the standards and directives valid at the time that modifica- tions are made.

  • Page 48: Damage, Defects And Misuse Of Safety Systems

    STILL.  CAUTION Installation and/or use of such products may there- fore have a negative impact on the design features of the truck and thus impair active and/or passive driving safety.

  • Page 49: Tyres

    Safety Basic principles for safe operation Tyres  DANGER Risk to stability! Failure to observe the following information and in- structions can lead to a loss of stability. The truck may tip over, risk of accident! The following factors can lead to a loss of stability and are therefore prohibited: Different tyres on the same axle, e.g.

  • Page 50: Medical Equipment

    Safety Basic principles for safe operation Medical equipment  WARNING Electromagnetic interference may occur on medical devices! Only use equipment that is sufficiently protected against electromagnetic interference. Medical equipment, such as pacemakers or hearing aids, may not work properly when the truck is in operation.

  • Page 51: Length Of The Fork Arms

    Safety Basic principles for safe operation Length of the fork arms  DANGER Risk of accident due to the incorrect selection of fork arms! – The fork arms must match the depth of the load. If the fork arms are too short, the load may fall off the arms after it has been picked up.

  • Page 52: Residual Risk

    Safety Residual risk Residual risk Residual dangers, residual risks Despite working with care and complying with the standards and regulations, the possibility of other dangers arising when using the truck cannot be ruled out. The truck and all other system components comply with current safety requirements.

  • Page 53: Special Risks Associated With Using The Truck And Attachments

    Safety Residual risk ments, this can lead to an accident. In this case, the manufacturer is exempt from liability. Stability The stability of the truck has been tested to the latest technological standards. If the truck is used in the proper manner and in accord- ance with its intended use, the stability of the truck is guaranteed.
  • Page 54 Safety Residual risk use the truck correctly and without the risk of accidents.  40 55048015301 EN - 12/2023  -  07...
  • Page 55 Safety Residual risk 55048015301 EN - 12/2023  -  07  41...

  • Page 56: Overview Of Hazards And Countermeasures

    Safety Residual risk Overview of hazards and countermeasures NOTE This table is intended to help evaluate the hazards in your facility and applies to all drive types. It does not claim to be complete. – Observe the national regulations for the country in which the truck is being used.
  • Page 57 Safety Residual risk Hazard Course of action Check note Notes √ done - Not applicable Impermissible usage Provide operating in- German Ordinance on (improper usage) structions Industrial Safety and Health (BetrSichV) and German Health and labour protection law (ArbSchG) Written notice of in- German Ordinance on struction to driver Industrial Safety and...

  • Page 58: Danger To Employees

    Safety Residual risk Hazard Course of action Check note Notes √ done - Not applicable DGUV rule 113-001 and observe the oper- ating instructions When operating driverless transport systems Roadway quality inad- Clean/clear roadways German Ordinance on equate Industrial Safety and Health (BetrSichV) Loading equipment in- Reposition load on pal-...
  • Page 59 Safety Residual risk The design and equipment of the truck comply with the standards and directives required for CE conformity. The design and equipment al- so comply with the standards and directives necessary for the UKCA compliance that is required in the United Kingdom. The design and equipment are therefore not part of the required scope of the hazard assessment.

  • Page 60: Safety Tests

    Safety Safety tests Safety tests Carrying out regular inspections  on the truck The operating company must ensure that the truck is checked by a specialist at least once a year or after particular incidents. As part of this inspection, the technical condi- tion of the truck must be completely tested with regard to accident safety.
  • Page 61 Safety Safety tests The exact procedure for this insulation testing is described in the workshop manual for this truck. NOTE The truck's electrical system and drive batter- ies must be checked separately. Test values for the drive battery Recommended Nominal volt- Component Measurements Test values...

  • Page 62: Regularly Testing The Electrical Safety

    Safety Safety tests Regularly testing the electrical  safety The on-board charger and the associated charging cable must be tested at least once a year. This test must be carried out in ac- cordance with the national regulations for the country of use (e.g.

  • Page 63: Safety Regulations For Handling Consumables

    Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables  WARNING Consumables can be dangerous! – Observe general information and safety informa- tion regarding the use of consumables. – Refer to the chapter entitled "Safety regula- tions for handling consumables". –...

  • Page 64: Hydraulic Fluid

    Safety Safety regulations for handling consumables  WARNING Prolonged intensive contact with the skin can result in dryness and irritate the skin! – Avoid contact and consumption. – Wear protective gloves. – After any contact, wash the skin with soap and water, and then apply a skin care product.

  • Page 65: Battery Acid

    Safety Safety regulations for handling consumables  WARNING These fluids are pressurised during op- eration of the truck and are hazardous to your health. – Do not allow the fluids to come into contact with the skin. – Avoid inhaling spray. –...

  • Page 66: Brake Fluid

    Safety Safety regulations for handling consumables  WARNING Battery acid contains dissolved sulphuric acid. This is corrosive. – When working with battery acid, use appropriate PSA (rubber gloves, apron, protection goggles). – When working with battery acid, nev- er wear a watch or jewellery. –...
  • Page 67 Safety Safety regulations for handling consumables  WARNING Brake fluid is hazardous to your health! Brake fluid irritates the eyes and can dry out the skin upon prolonged contact. – Coat your hands with a protective skin cream prior to starting work. –...

  • Page 68: Disposal Of Consumables

    Safety Safety regulations for handling consumables Disposal of consumables ENVIRONMENT NOTE Materials that accumulate during repair, main- tenance and cleaning must be collected prop- erly and disposed of in accordance with the national regulations for the country in which the truck is being used. Work must only be carried out in areas designated for the pur- pose.

  • Page 69: Emissions

    Safety Emissions Emissions The values specified apply to a standard truck (compare the specifications in the "Technical data" chapter). Different tyres, lift masts, addi- tional units etc. may produce different values. Noise emissions The values were determined based on meas- uring procedures from the standard EN 12053 "Safety of industrial trucks - Test methods for measuring noise emissions", based on...
  • Page 70 Safety Emissions Vibrations The vibrations of the machine have been de- termined on an identical machine in accord- ance with the standards DIN EN 13059 "Safe- ty of industrial trucks - Test methods for meas- uring vibration" and DIN EN 12096 "Mechani- cal vibration - Declaration and verification of vibration emission values".
  • Page 71 – Observe the safety regulations for handling the battery. Radiation In accordance with the guide- lines DIN EN 62471:2009-03 (VDE 0837-471:2009-03), the STILL Safety- Light and the warning zone light (variant) are assigned to risk group 2 (medium risk) due to their photobiological hazard potential. 55048015301 EN - 12/2023  -  07...
  • Page 72 Safety Emissions  58 55048015301 EN - 12/2023  -  07...

  • Page 73: Overviews

    Overviews...

  • Page 74: Overview

    Overviews Overview Overview Left-hand side view Rear view 5510_003-009 5510_003-008 Lift mast Counterweight Overhead guard Connection for towing bracket / tow coupling Driver's compartment (optional) Battery hood Drive wheel Running axle Fork arms Fork carriage  60 55048015301 EN - 12/2023  -  07...
  • Page 75 Overviews Overview 55048015301 EN - 12/2023  -  07  61...

  • Page 76: Driver's Compartment

    Cup holder for bottles with a maximum size Emergency off switch of 1.0 litres Key switch/push button Battery hood handle Compartment Driver's seat Display-operating unit "STILL Easy Control" Support mounting for storing the hexagon Accelerator pedal socket wrench for emergency lowering Operating devices for hydraulics and driving Brake pedal functions Currently not occupied.

  • Page 77: Shelf And Cup Holder

    Overviews Shelf and cup holder NOTE The truck equipment may differ from the equipment shown. Shelf and cup holder   WARNING Risk of accident caused by blocked pedals! Objects may fall into the footwell during travel as a result of steering or braking. They can slip between and under the pedals (2).

  • Page 78: Operating Devices And Display Elements

    Right-hand favourites bar Brightness sensor "STILL Easy Control" is a third-generation dis- play-operating unit for industrial trucks. It is used as an operating device for the usu- al functions of the truck, such as controlling lighting and windscreen wiper functions and adjusting the driving dynamics.

  • Page 79: Emergency Off Switch

    – For information about the other display op- tions, see the original operating instructions entitled "STILL Easy Control display-operat- ing unit". The display-operating unit is attached to the armrest, except in trucks equipped with mul- ti-lever operation.

  • Page 80: Multi-Lever Operation

    Overviews Operating devices and display elements Multi-lever operation 5510_003-038_V2 Drive direction switch "Tilt" operating lever Signal horn button Operating lever for attachments (variant) "Lift/lower" operating lever Operating lever for attachments (variant) NOTE In the dual-pedal version (variant), the drive direction switch (1) is used exclusively to acti- vate the cruise control function (variant).

  • Page 81: Double Mini-Lever

    Overviews Operating devices and display elements Double mini-lever Drive direction switch "F1" function key Cross lever "Attachments" "Lift mast" 360° lever Function key for the "5th function" Display field for the hydraulic functions Signal horn button 55048015301 EN - 12/2023  -  07  67...
  • Page 82 Overviews Operating devices and display elements NOTE In the dual-pedal version (variant), the drive ● direction switch (1) is used exclusively to activate the cruise control function (variant). The drive direction is selected exclusively via the pedals in the dual-pedal version. The authorised service centre can assign ●...

  • Page 83: Triple Mini-Lever

    Overviews Operating devices and display elements Triple mini-lever Drive direction switch Signal horn button "Auxiliary hydraulics 1" operating lever "F1" function key "Auxiliary hydraulics 2" operating lever "Lift mast" 360° lever Function key for the "5th function" Display field for the hydraulic functions 55048015301 EN - 12/2023  - ...
  • Page 84 Overviews Operating devices and display elements NOTE In the dual-pedal version (variant), the drive ● direction switch (1) is used exclusively to activate the cruise control function (variant). The drive direction is selected exclusively via the pedals in the dual-pedal version. The authorised service centre can assign ●...

  • Page 85: Quadruple Mini-Lever

    Overviews Operating devices and display elements Quadruple mini-lever Drive direction switch Signal horn button "Tilt" operating lever "F1" function key "Auxiliary hydraulics 1" operating lever "Lift/lower" operating lever "Auxiliary hydraulics 2" operating lever Display field for the hydraulic functions Function key for the "5th function" 55048015301 EN - 12/2023  - ...
  • Page 86 Overviews Operating devices and display elements NOTE In the dual-pedal version (variant), the drive ● direction switch (1) is used exclusively to activate the cruise control function (variant). The drive direction is selected exclusively via the pedals in the dual-pedal version. The authorised service centre can assign ●...

  • Page 87: Fingertip

    Overviews Operating devices and display elements Fingertip Signal horn button Drive direction switch LED for the "5th function" "Lift/lower" operating lever Function key for the "5th function" "Tilt" operating lever LED for the "Clamp release" "F1" function key Operating lever for "Auxiliary hydraulics 1" LED for "F1"...

  • Page 88: Joystick 4Plus

    Overviews Operating devices and display elements Joystick 4Plus 6219_003-210_V2 Horizontal rocker button for the "3rd and LED for the "clamp release" (variant) 4th hydraulic function": tilting the lift mast Slider for the "4th hydraulic function" Pictograms for the hydraulic functions: lift- Vertical rocker button for the "drive direction" ing, lowering and sideshift Shift key "F"...

  • Page 89: Travel Direction Selector And Indicator Module (Variant)

    Overviews Operating devices and display elements Travel direction selector and in-  dicator module (variant) The travel direction selector and indicator module is located on the steering column be- low the steering wheel. NOTE If the drive direction switch on the operating device is defective and the truck stops in a danger area, the drive direction selection lever on the travel direction selector and indicator...
  • Page 90 Overviews Operating devices and display elements  76 55048015301 EN - 12/2023  -  07...

  • Page 91: Operation

    Operation...

  • Page 92: Checks And Tasks Before Daily Use

    Operation Checks and tasks before daily use Checks and tasks before daily use Visual inspections and function checking  WARNING Risk of injury from falling off the truck! When climbing onto the truck, there is a risk of getting stuck or slipping and falling.
  • Page 93 Operation Checks and tasks before daily use Component Course of action Ensure that the attachments are mounted correctly in accordance with the operating instructions from the manufacturer. Attachments (variant) Perform a visual inspection to ensure that the at- tachments are intact and are leak-tight. Perform checks to ensure that the attachments are working correctly.
  • Page 94 Operation Checks and tasks before daily use Component Course of action Inspect the battery male connector and the plug connection for moisture or any foreign objects that may have become lodged and remove as necessa- ry, e.g. using compressed air. Battery male connector and plug connec- Perform a visual inspection for integrity and defor- tion...
  • Page 95 Perform a visual inspection for integrity. Ensure cleanliness. Make sure that the antistatic belt(3) is still long Antistatic belt (3), corona electrode (4) enough to touch the ground in all situations. (See the following illustration.) The discharge wires of the corona electrode (4)

  • Page 96: Climbing Into And Out Of The Truck

    Operation Checks and tasks before daily use Climbing into and out of the truck  WARNING Risk of injury when climbing into and out of the truck due to slipping, striking parts of the truck or becom- ing stuck! If the footwell cover is very dirty or smeared with oil, there is a risk of slipping.

  • Page 97: Adjusting The Driver's Seat And Armrest

    Operation Checks and tasks before daily use To assist with climbing into and out of the  truck, the footwell (4) must be used as a step and the handle (1) must be used for support. The post of the overhead guard (2) can also be used for support.

  • Page 98: Function Checking Of The Assistance Systems

    Operation Checks and tasks before daily use To change the resistance for adjusting the dis-  play-operating unit, there are two socket head screws (2) on the support for the display-op- erating unit. The hexagon socket wrench for emergency lowering can be used to loosen or tighten the socket head screws (2).
  • Page 99 Operation Checks and tasks before daily use NOTE The fleet manager can configure some assis- tance systems. – Check whether the assistance systems are correctly configured for daily use. – If they are not, have the configuration cor- rected by the fleet manager. 55048015301 EN - 12/2023  - ...

  • Page 100: Unlock The Emergency Off Switch

    Operation Checks and tasks before daily use Unlock the emergency off switch  – Turn the emergency off switch (1) clockwise until it pops out. Checking the emergency off  function  WARNING No electric braking assistance is available when the emergency off switch is actuated! Actuating the emergency off switch disconnects the drives from the power supply.

  • Page 101: Operating The Signal Horn

    Operation Checks and tasks before daily use Operating the signal horn  The signal horn is used to warn people against imminent danger or to announce your intention to overtake. – Press the signal horn button (1). The signal horn sounds. 5510_003-039 55048015301 EN - 12/2023  - ...

  • Page 102: Driver's Cab

    Operation Checks and tasks before daily use Driver's cab  DANGER Risk of fatal injury in the event of falling from the truck if it tips over! In order to prevent the driver from sliding underneath the truck and being crushed if the truck tips over, a restraint system must be in place and must be used.

  • Page 103: Checking The Brake System For Correct Function

    Operation Checks and tasks before daily use Checking the brake system for correct function  DANGER Risk of accident in the event of failure of the brake system! If the brake system fails, the truck will be insufficient- ly braked. – Do not operate the truck if the brake system is faulty.
  • Page 104 Operation Checks and tasks before daily use – Accelerate the unladen truck in a clear area. – Press the brake pedal (1) firmly. The truck must decelerate noticeably. Checking the parking brake on a gradi- ent or a lorry ramp  DANGER Risk to life if the truck rolls away! If the parking brake is not applied, the truck could run people over.

  • Page 105: Warming Up The Hydraulic Oil At Cold Ambient Temperatures

    Operation Checks and tasks before daily use NOTE When the emergency off switch is actuated, note the following: The electric brake is disabled. The truck no ● longer responds to the command issued by the accelerator pedal. The power steering is no longer available. ●...

  • Page 106: Checking The Steering System For Correct Function

    Operation Checks and tasks before daily use  WARNING Risk of short circuit and fire during continuous lifting, lowering and tilting! If the lifting function, the lowering function or the tilt function are used against the stop for more than one minute, there is a risk of short circuit and fire.

  • Page 107: Driver's Seat

    Operation Driver's seat Driver's seat Adjusting the MSG 65 and MSG 75 driver's seat  WARNING Risk of accident from sudden adjustment of the seat or of the seat backrest! The inadvertent adjustment of the seat or of the seat backrest can lead to uncontrolled movements by the driver.
  • Page 108 Operation Driver's seat Moving the driver's seat  – Raise the lever (1) and hold it in position. – Push the driver's seat into the required po- sition. – Release the lever. – Ensure that the driver's seat is securely en- gaged.
  • Page 109 Operation Driver's seat Adjusting the MSG 65/MSG 75 seat  suspension NOTE The MSG 65/MSG 75 driver's seat is de- signed for people weighing between 45 kg and 170 kg. The driver's seat can be adjusted to suit the weight of the individual driver. To ob- tain optimal settings for the seat suspension, the driver must perform the adjustment whilst sitting on the seat.
  • Page 110 Operation Driver's seat The seat automatically adjusts to the driver's weight. Adjusting the longitudinal horizontal  suspension (variant) If the driver's seat is equipped with the "longi- tudinal horizontal suspension" variant, impacts in the drive direction are damped by additional seat suspension.
  • Page 111 Operation Driver's seat Adjusting the backrest extension (var-  iant) – Adjust the backrest extension (7) by pulling it out or pushing it into the desired position. To remove the backrest extension, move it past the end stop by firmly pushing it upwards. 6321_003-040_V3 Switching the seat heater (variant) on ...

  • Page 112: Seat Belt

     DANGER Risk of injury if the truck tips over! Even if an approved restraint system is in use, there is still a residual risk that the driver could be injured if the truck tips over. This risk of injury can be reduced through the combined use of the re- straint system and the seat belt.
  • Page 113 Operation Driver's seat NOTE The buckle has a buckle switch. When the belt was not fastened, the following occurred: The message Close seat belt   ● appears on the display-operating unit. The truck will not drive at speeds faster ● than 4 km/h.
  • Page 114 Operation Driver's seat Fastening on a steep slope  The automatic blocking mechanism prevents the belt from being extended whenever the truck is on a steep gradient. It is no longer possible to pull the seat belt out of the belt retractor.

  • Page 115: Adjusting The Armrest

    Operation Driver's seat  CAUTION The seat belt may be damaged by heat! Do not subject the buckle or belt retractor to exces- sive heat when thawing. – Do not use air warmer than 60°C when thawing. Adjusting the armrest  DANGER There is a risk of accident if the armrest lowers suddenly, causing the driver to move in an uncon- trolled manner.

  • Page 116: Switching On

    Operation Switching on Switching on Switching on using the key switch  WARNING All checks and tasks required before daily use must have been performed without any defects being iden- tified before switching on the truck. – Perform the "visual inspections and functional checks".

  • Page 117: Switching On Via Push Button (Variant)

    Operation Switching on – Refer to the chapter entitled "Display mes- sages". NOTE After connecting the battery, the correct charge state may not be displayed until the battery is placed under load by driving or lifting operations. Switching on via push button (variant)  WARNING All checks and tasks required before daily use must...
  • Page 118 Operation Switching on – To switch off the truck, press the push but- ton (1) and hold for 1 second. NOTE For the variant with "Access authorisation with PIN code", see ● the relevant section. "FleetManager", see the "original operating ● instructions for FleetManager".  104 55048015301 EN - 12/2023  - ...

  • Page 119: Display-Operating Unit

    Operation Display-operating unit Display-operating unit Operating the display-operating unit 08:20 7° 2,71 km/h 6219_003-310 The display-operating unit is operated using the control and enter keys (5...8) and the soft- keys (4, 10). The display (2) shows informa- tion about the current driving programme, load programme and the configuration of the fa- vourites bars (1, 3).

  • Page 120: Access Authorisation With Pin Code (Variant)

    Operation Display-operating unit Functions of the control and enter keys Designation Position Functions The softkeys correspond to the adjacent functions or input options. If functions have been stored in the favourites bars (1, 3), these functions can be switched on and off by pressing the Softkeys 4, 10 adjacent softkey.
  • Page 121 Operation Display-operating unit When the key switch is switched on, the  input menu ap- Access authorisation pears. All hydraulic functions and drive functions of the truck are blocked. In the StVZO (German Road Traffic Licensing Regulations) variant, the function of the hazard warning system (variant) is guaranteed.

  • Page 122: Access Authorisation For The Fleet Manager (Variant)

    Operation Display-operating unit – Press the   softkey.  Service – Press the scroll keys    until the  menu appears. Change PIN codes – Press the softkey. Change PIN codes Calibration – Follow the instructions on the display. Relieve hydraulics Shock sensor Change password (access auth.) Change PIN codes...
  • Page 123 Operation Display-operating unit date, the authorised service centre must set up a fleet manager password. Standard fleet manager password The standard fleet manager password is "1111". For safety reasons, this standard fleet manager password must be changed af- ter the first use. See also the section en- titled "Changing the fleet manager pass- word".
  • Page 124 Operation Display-operating unit The display changes to the  Access au- menu. thorisation – Enter the fleet manager password using the softkeys. – To confirm, press the button. Enter password 6219_003-208_V3_en The message  Fleet manager access   appears. authorisation granted –...
  • Page 125 Operation Display-operating unit – Press the   softkey.  Service – Press the scroll buttons    until  Change password (access menu appears. auth.) – Press the Version list Change password (ac- softkey. cess auth.) – Follow the instructions on the display. Calibration Relieve hydraulics Shock sensor...

  • Page 126: Pre-Shift Check

    Operation Pre-Shift Check Pre-Shift Check Description of the Pre-Shift Check (variant) The Pre-Shift Check is a guided dialogue in the display-operating unit. It also helps the driver conduct the necessary "visual inspec- tions and function checking" before everyday use. After the truck has been switched on, the driver must answer questions about the condi- tion of the forklift truck with While the driver is doing this, the truck func-...

  • Page 127: Process

    The main display contains the message To complete Pre-Shift Check,   press This means that the Pre-Shift Check is still active and the truck functions are restricted. – To acknowledge the message, press the 6219_003-265_en  softkey. – Switch on and check the function to be tes- ted, e.g.

  • Page 128: All Questions

    Operation Pre-Shift Check speed. When the parking brake is applied again, the view returns to Pre-Shift Check. At the end of the check, truck functions are restricted if they have been adjusted as a re- action to a negative test result. The message Pre-Shift Check truck restric- shows that truck functions tions active...

  • Page 129: Defining The Question Sequence

    Operation Pre-Shift Check Is the capacity rating plate present, undamaged, and legible? Is the driver restraint system damaged? Does the horn work? Does the truck lighting work? Do the warning lights work? Is the antistatic belt present and does it have sufficient con- tact with the floor? Is the corona electrode present and clean? Does the parking brake work properly?
  • Page 130 Operation Pre-Shift Check – Press the   softkey.  Service – Press the scroll keys    until the  Pre- menu appears. Shift Check – Press the  softkey. Pre-Shift Check Message list Maintenance interval Version list Pre-Shift Check Calibration Fleet manager 6219_003-268_en  116 55048015301 EN - 12/2023  - ...

  • Page 131: Displaying The History

    Operation Pre-Shift Check menu appears.  Pre-Shift Check – Press the  softkey. Question sequence History Reset restriction Shift start Question sequence Fleet manager 6219_003-269_en Pressing the softkey allows fixed or random  question sequences to be selected. The orange activation bar displays the current selection.
  • Page 132 Operation Pre-Shift Check – Press the   softkey.  Service – Press the scroll keys    until the  Pre- menu appears. Shift Check – Press the  softkey. Pre-Shift Check Message list Maintenance interval Version list Pre-Shift Check Calibration Fleet manager 6219_003-268_en  118 55048015301 EN - 12/2023  - ...

  • Page 133: Defining The Shift Start

    Operation Pre-Shift Check menu appears.  Pre-Shift Check – Press the softkey. History History Reset restriction Shift start Question sequence Fleet manager 6219_003-269_en The Pre-Shift Check display opens.  results This display shows all checks and questions that have been answered with the date and Pre-Shift Check results time.
  • Page 134 Operation Pre-Shift Check NOTE If the truck is equipped with the "FleetManag- er" variant, the shifts are defined on the Fleet- Manager interface. See the relevant operating instructions. – Activate the "Access authorisation for the fleet manager". – Press the  ...
  • Page 135 Operation Pre-Shift Check menu appears.  Pre-Shift Check – Press the  softkey. Shift start History Reset restriction Shift start Question sequence Fleet manager 6219_003-269_en In this menu, you can call up the shift to be  defined and its start time. The orange activation bar indicates which shifts are activated.
  • Page 136 Operation Pre-Shift Check In this menu you can define the shift start.  – Enter the time using softkeys  0 to 9 – To , press the  button. save Shift start 1 The shift start is now defined. The Pre-Shift Check is always requested from this shift start time.

  • Page 137: Resetting The Truck Restrictions

    Operation Pre-Shift Check – Press the scroll button to deactivate the  shift. – To confirm, press the button. Shift start 1 The time is shown in grey. The shift is deactivated. The display reverts to the previous menu. There is no activation bar next to this shift.
  • Page 138 Operation Pre-Shift Check – Press the scroll keys    until the  Pre- menu appears. Shift Check – Press the  softkey. Pre-Shift Check Message list Maintenance interval Version list Pre-Shift Check Calibration Fleet manager 6219_003-268_en menu appears.  Pre-Shift Check –...
  • Page 139 Operation Pre-Shift Check A question pops up asking if you want to reset  the truck restrictions. – To confirm, press the  softkey. The full scope of the truck functions is now available. The display reverts to the previous Reset the truck restrictions? The entry remains in the history menu.

  • Page 140: Driver Profiles

    Operation Driver profiles Driver profiles Driver profiles (variant)  This variant allows up to ten individual driver profiles to be created. The driver is greeted with the selected name after logging in. Once  softkey is pushed, the main display appears. Hello, 0,0°...
  • Page 141 Operation Driver profiles NOTE Access to the settings menu is only availa- ble if the truck is at a standstill and the park- ing brake is applied. If the parking brake is released prematurely, the settings menu will close. – Stop the truck. –...

  • Page 142: Creating Driver Profiles

    Operation Driver profiles Creating driver profiles Both the fleet manager and the driver can cre- ate up to ten driver profiles. NOTE If the truck is equipped with the "Access au- thorisation with PIN code" or "FleetManager" variants, the driver profile is generated auto- matically when logging in for the first time.

  • Page 143: Renaming Driver Profiles

    Operation Driver profiles menu is displayed.  Driver name – Use the softkeys to enter the desired name. – To confirm, press the button. Driver name The driver profile is active. The driver is gree- ted with the selected name after the next log- Any changes that drivers make to the settings Enter driver name while they are logged in are saved.
  • Page 144 Operation Driver profiles – Press the  Rename driver profiles softkey. Driving programme Rename driver profiles 6219_003-298_en menu is displayed.  Driver name – Use the softkeys to enter the desired name. – To confirm, press the button. Driver name Renaming by the fleet manager –...
  • Page 145 Operation Driver profiles – Press the  Manage driver pro-  softkey. files Lift height preselection Auxiliary hydraulics Change PIN codes Manage driver profiles On-board charger Fleet manager 6219_003-296_en – Press the  Rename driver pro-  softkey. files Rename driver profiles Delete driver profiles Fleet manager 6219_003-297_en...

  • Page 146: Deleting Driver Profiles

    Operation Driver profiles menu is displayed.  Driver name – Use the softkeys to enter the desired name. – To confirm, press the button. Driver name Enter driver name Horst = Clear = abc -> ABC = Save = Cancel 6219_003-295_en Deleting driver profiles The fleet manager has access authorisation to...
  • Page 147 Operation Driver profiles – Press the  Delete driver profiles softkey. Rename driver profiles Delete driver profiles Fleet manager 6219_003-297_en – Press the softkey for the driver profile to be  deleted. The driver profile is deleted. Guido Horst Lisa Driver 4 Available storage position 5 6219_003-294_en...

  • Page 148: Lighting

    Symbols for the lighting and their meanings Parking light Headlights Hazard warning system Rotating beacon STILL SafetyLight Warning zone light Front working spotlights Rear working spotlights Roof working spotlights Only the symbols of the lighting devices that are installed in the truck can be selected.

  • Page 149: Driving Lights

    Operation Lighting Driving lights  – To switch on the parking light (1), push the associated Softkey on the display-operating unit. The front side lights and the tail lights light up. – To switch on the driving light (2), press the associated Softkey on the display-operating unit.

  • Page 150: Working Spotlights

    Operation Lighting Working spotlights Front and rear working spotlights  – To switch on the front working spot- lights (3), push the associated Softkey on the display-operating unit. The front working spotlights light up. – To switch off the front working spot- lights (3), push the Softkey again.

  • Page 151: Working Spotlight For Reverse Travel (Variant)

    Operation Lighting Working spotlight for reverse travel (variant) In this equipment variant, a working spotlight for reverse travel is fitted on the rear of the overhead guard and provides optimum illumi- nation of the roadway during reverse travel. – Press the  softkey.
  • Page 152 Operation Lighting – To switch on the left or right turn indicator,  move the lever (1) to the desired direction. 6219_003-098 The turn indicators and the turn indicator dis-  play (2) or (3) on the display-operating unit flash. 08:20 – To switch off the turn indicators, push the lever (1) back to the centre position.

  • Page 153: Hazard Warning System

    Operation Lighting Hazard warning system  Switching the hazard warning system on and off is different for trucks with and without the StVZO (German Road Traffic Licensing Regu- lations) variant. – To switch on the hazard warning system, push the associated Softkey on the display- operating unit.

  • Page 154: Stvzo Equipment

    This softkey is used to switch off all light- ing devices that are not permitted on roads subject to German traffic regulations (StVO). This relates to the following variants of lighting equipment: STILL SafetyLight and STILL Safety- ● Light 4Plus Warning zone light and warning zone light ●...

  • Page 155: Rotating Beacon

     WARNING Danger of damage to eyes from look- ing into the STILL SafetyLight® and STILL SafetyLight 4Plus®. Do not look into the STILL SafetyLight® or STILL SafetyLight 4Plus®. STILL SafetyLight® and STILL SafetyLight 4Plus® are visual warning units designed to enable early detection of trucks in driving areas with low visibility (such as drive lanes, high racks), as well as at blind junctions.

  • Page 156: Warning Zone Light And Warning Zone Light Plus (Variants)

    STILL SafetyLight 4Plus® is mounted on a support on the overhead guard such that it is not affected by jolts and vibrations. Depending on the version, the STILL Safety- Light® projects one or more light-blue light spots in front of or behind the truck and thus warns others about the approaching truck.
  • Page 157 Operation Lighting The warning zone light projects a light bar  next to the truck on both the left-hand side and right-hand side of the truck or even behind the truck. This light bar indicates the danger areas to the sides or rear of the truck while in operation.

  • Page 158: Efficiency And Drive Modes

    Operation Efficiency and drive modes Efficiency and drive modes STILL Classic and sprint mode  The drive modes affect the handling of the truck. Two different drive modes are available: STILL Classic This mode is the reduced acceleration setting and provides a balance between hydraulic functions and driving functions.
  • Page 159 Operation Efficiency and drive modes The battery voltage and the temperature of the traction drives and energy supply are moni- tored continuously. If under voltage (does not apply to lithium-ion batteries) or overheating occurs, sprint mode is automatically deactiva- ted. If the truck is automatically switched off due to under voltage, sprint mode can then only be switched on again if the following conditions...

  • Page 160: Driving

    Operation Driving Driving Safety regulations when driving Driving conduct The driver must follow the public rules of the road when driving in company traffic. The speed must be appropriate to the local conditions. For example, the driver must drive slowly around corners, in tight passageways, when driving through swing-doors, at blind spots, or on uneven surfaces.
  • Page 161 There is a risk of accident! – Do not use devices during travel or when handling loads. – Set the volume so that warning signals can still be heard.  WARNING In areas where use of mobile phones is prohibited, use of a mobile phone or radio telephone is not per- mitted.

  • Page 162: Roadways

    Operation Driving Roadways Dimensions of roadways and aisle widths The following dimensions and aisle width re- quirements apply under the specified condi- tions to ensure safe manoeuvring. In each case, a check must be performed to determine whether a larger aisle width is necessary, e.g. in the case of deviating load dimensions, at- tachments, lift masts and tow couplings.
  • Page 163 Operation Driving Driving on gradients  WARNING Risk of accident due to the drive unit switching off! Driving up and down longer gradients can cause the drive unit to overheat and switch off. The truck will then no longer decelerate when the accelerator ped- al is released and will coast.
  • Page 164 Operation Driving Warning in the event that components protrude beyond the truck contour Trucks are often required to drive through very narrow or very low spaces such as aisles or containers. The dimensions of the trucks are designed for this purpose. However, movable components may protrude beyond the truck contour and be damaged or torn off.

  • Page 165: Selecting Drive Programmes 1 To 3

    Operation Driving Hazardous areas Hazardous areas on roadways must be indica- ted by standard traffic signs or, if necessary, by additional warning signs. Selecting drive programmes 1 to  The truck has three drive programmes with different preset driving and braking character- istics.

  • Page 166: Configuring Drive Programmes A And B

    Operation Driving Selecting drive programme A or  The truck has two driving programmes for personalised handling and braking character- istics. Unlike the fixed drive programmes "1 to 3", the programs "A" and "B" can be configured. The procedure for this is described in the following section.
  • Page 167 Operation Driving – Press the associated softkey for drive programme A drive programme Configuration of the drive programmes using is explained here. drive programme A menu ap-  Setdrive programme A pears. The following parameters can be set: ● Max. speed Determines the maximum speed (varies de- pending on the truck model).

  • Page 168: Selecting The Drive Direction

    Operation Driving Selecting the drive direction  The drive direction of the truck must be selec- ted using the drive direction switch/drive direc- tion selection lever before attempting to drive. The method of actuating the drive direction switch/drive direction selection lever depends on the operating devices that are fitted in the truck.

  • Page 169: Actuating The Drive Direction Switch With The Multiple-Lever Version

    Operation Driving Actuating the drive direction  switch with the multiple-lever version – For the "forwards" drive direction, push the drive direction switch (1) downwards. – For the "backwards" drive direction, push the drive direction switch (1) upwards. NOTE If the drive direction switch (1) is defective and the truck stops in a danger area, the drive direction selection lever on the travel direction selector and indicator module (variant) can be...

  • Page 170: Joystick 4Plus Version

    Operation Driving Actuating the drive direction  switch with the Fingertip version – For the "forwards" drive direction, push the drive direction switch (1) forwards. – For the "backwards" drive direction, pull the drive direction switch (1) backwards. NOTE If the drive direction switch (1) is defective and the truck stops in a danger area, the drive direction selection lever on the travel direction selector and indicator module (variant) can be...

  • Page 171: Indicator Module Version

    Operation Driving Actuating the drive direction se-  lection lever with the travel direc- tion selector and indicator mod- ule version – For the "forwards" drive direction, push the drive direction selection lever (1) forwards. – For the "backwards" drive direction, push the drive direction selection lever (1) back- wards.
  • Page 172 Depending on the equipment, the following variants of warning units for reverse travel may be present: An acoustic signal will be heard. ● The STILL SafetyLight lights up. ● The hazard warning system flashes. ● – Press the accelerator pedal (3).

  • Page 173: Starting Drive Mode, Dual Pedal Version (Variant)

    If the truck still cannot be operated, park the truck securely and con- tact the authorised service centre.
  • Page 174 Depending on the equipment, the following variants of warning units for reverse travel may be present: An acoustic signal will be heard. ● The STILL SafetyLight lights up. ● The hazard warning system flashes. ● The truck travels in the selected drive direc- tion.

  • Page 175: Operating The Service Brake

    If the truck still cannot be operated, park the truck securely and con- tact the authorised service centre.
  • Page 176 Operation Driving  DANGER At speeds that are too high, there is a danger that the truck could slip or overturn! The braking distance of the truck depends on the weather conditions and the level of contamination on the roadway, among other things. Note that the basic braking distance increases with the square of the speed.

  • Page 177: Actuating The Parking Brake

    Operation Driving is then available again. The message disap- pears. Actuating the parking brake  DANGER There is a risk of fatal injury from being run over if the truck rolls away. – The truck must not be parked on a slope.
  • Page 178 Operation Driving NOTE The parking brake lever swivels to the forward position automatically via spring force and re- quires only gentle manual guidance. If the movement of the parking brake is stiff, notify the authorised service centre. After the parking brake has been released, the previously selected drive direction is retained and is shown on the drive direction indicator.
  • Page 179 Operation Driving Cause Effect A warning signal sounds. Sitting in the driver's seat silences the warning The parking brake has been applied but has signal. not been applied correctly as a result of a mal- Use wedges to prevent the truck from rolling function The driver's seat is vacated.

  • Page 180: Steering

    Operation Driving Steering   DANGER Risk of accident! If the hydraulics fail, there is a risk of accident as the steering characteristics will have changed. – Do not operate the truck if it has a defective steer- ing system. – Steer the truck by turning the steering wheel (1) accordingly.

  • Page 181: Reducing Speed When Turning (Curve Speed Control)

     DANGER The Curve Speed Control function cannot override the physical limits of stability. Despite this function, there still is a risk of tipping! – Before using this function, familiarise yourself with the change to the driving and steering characteris- tics of the truck.

  • Page 182: Speed Restriction (Variant)

    Operation Driving Speed restriction (variant)  The speed restriction (variant) is a function that can be configured by the fleet manager. It sets a maximum speed that can either be permanent or be called up by the driver. This function helps the driver to comply with speed restrictions, e.g.
  • Page 183 Operation Driving The menu that opens offers the following func- tions: ● Permanent Enabling this function limits the speed until the fleet manager disables this function. ● By pressing a button If this function is activated, the driver may switch the speed restriction on and off by pressing the ...

  • Page 184: Cruise Control (Variant)

    Operation Driving Cruise control (variant)  The "cruise control" assistance function allows the driver to maintain a constant truck speed over a reasonable distance. In addition, the cruise control function can be used to comply with any speed restriction that is in force on the company's premises.
  • Page 185 Operation Driving – Press the  softkey.  The orange-coloured activation bar next to the 08:20  softkey lights up. The cruise control func- tion is ready. The greyed-out  symbol (1) appears on the display. Taking the cruise control function off standby Pressing the  softkey again takes the func- tion off standby.
  • Page 186 Operation Driving – Actuate the drive direction switch (2) for for-  wards travel. NOTE In the dual-pedal version (variant), the drive direction switch (2) is used exclusively to acti- vate and deactivate the cruise control function (variant). 5510_003-032  172 55048015301 EN - 12/2023  -  07...
  • Page 187 Operation Driving The cruise control function is active. The cur-  rent speed is saved. 08:20 Two beeps signal that the cruise control func- tion is active. The symbol (4) appears in black in the display. – Take your foot off the accelerator pedal. The truck continues to drive at the selected speed until the cruise control function is deac- tivated.
  • Page 188 Operation Driving Other conditions that will cause the truck con- trol unit to deactivate the cruise control func- tion are: Vacating the driver's seat ● Truck speed less than 2.5 km/h. ● Speed restriction set to less than 4.5 km/h. ● The truck control unit detects abnormalities, ●...

  • Page 189: Parking

    Operation Parking Parking Parking the truck securely and switching it off  DANGER There is a risk of fatal injury from being run over if the truck rolls away. – Do not park the truck on gradients. – In emergencies, secure the truck us- ing wedges on the side facing down- hill.
  • Page 190 Operation Parking – Lower the fork carriage to the ground.  – Tilt the lift mast forwards until the tips of the fork arms rest on the ground. – If attachments (variant) are fitted, retract the working cylinders; see the chapter entitled "General instructions for controlling attach- ments".

  • Page 191: Wheel Chock (Variant)

    Operation Parking – In the "push button ignition" variant, press  the button. (1) NOTE Switch keys, FleetManager cards (variant), FleetManager transponder chips (variant) and the PIN code for access authorisation (variant) must not be handed over to other persons unless explicit instructions to this effect have been given by the responsible fleet manager.

  • Page 192: Lifting

    Operation Lifting Lifting Lifting system variants The movement of the fork carriage and the lift mast heavily depends on the following equip- ment: The lift mast with which the truck is equip- ● ped, see C hapter "Lift mast versions", ⇒ ...

  • Page 193: Operating Devices For The Lifting System

    Operation Lifting NiHo lift mast (variant)  During lifting, the inner lift cylinder moves up to free lift (3) and then the outer lift cylinders raise the inner lift mast up to the maximum height (2). NOTE When lifting above the free lift, the fork car- riage always remains at the upper edge of the extending lift mast.
  • Page 194 Operation Lifting Fingertip ● Joystick 4Plus ● For clarity, the movements of the lifting system  are referred to by the letters (A, B, C, D) in this subchapter. Lower the fork carriage Lift the fork carriage Tilting the lift mast forwards Tilting the lift mast backwards –...

  • Page 195: Controlling The Lifting System Using Multi-Lever Operation

    Operation Lifting Controlling the lifting system us-  ing multi-lever operation  DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 196 Operation Lifting The pictograms are arranged according to the directions of movement of the operating lev- er (1) or (2). Lifting/lowering the fork carriage To lift the fork carriage: – Move the "lift/lower" operating lever (1) in the direction of the arrow (B). To lower the fork carriage: –...

  • Page 197: Controlling The Lifting System Using A Double Mini-Lever

    Operation Lifting Controlling the lifting system us-  ing a double mini-lever  DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 198 Operation Lifting NOTE The truck is configured at the factory in ac- ● cordance with the adhesive label (1). The following steps for moving the fork carriage and lift mast are based on this configura- tion. The configuration according to the adhesive ●...

  • Page 199: Controlling The Lifting System Using A Triple Mini-Lever

    Operation Lifting Controlling the lifting system us-  ing a triple mini-lever  DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 200 Operation Lifting NOTE The truck is configured at the factory in ac- cordance with the adhesive label (1). The fol- lowing steps for moving the fork carriage and lift mast are based on this configuration. Lifting/lowering the fork carriage To lift the fork carriage: –...

  • Page 201: Controlling The Lifting System Using A Quadruple Mini-Lever

    Operation Lifting Controlling the lifting system us-  ing a quadruple mini-lever  DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 202 Operation Lifting The pictograms are arranged according to the directions of movement of the operating lev- er (3) or (4). Lifting/lowering the fork carriage To lift the fork carriage: – Move the "lift/lower" operating lever (3) in the direction of the arrow (B). To lower the fork carriage: –...
  • Page 203 Operation Lifting Controlling the lifting system us-  ing the Fingertip  DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...

  • Page 204: Controlling The Lifting System Using The Joystick 4Plus

    Operation Lifting The pictograms are arranged according to the directions of movement of the operating lev- er (4) or (1). Lifting/lowering the fork carriage To lift the fork carriage: – Move the "lift/lower" operating lever (4) in the direction of the arrow (B). To lower the fork carriage: –...
  • Page 205 Operation Lifting  WARNING Risk of short circuit in the event of prolonged actua- tion of the working hydraulics! If the working hydraulics (e.g lifting function, tilt func- tion, auxiliary hydraulics function) are activated for longer than 1 minute against the stop/end position, there is a risk of short circuit.
  • Page 206 Operation Lifting Lifting/lowering the fork carriage  To lift the fork carriage: – Pull the Joystick 4Plus (1) backwards (B). To lower the fork carriage: – Push the Joystick 4Plus (1) forwards (A). 6219_003-167_V3 Tilting the lift mast  To tilt the lift mast forwards: –...

  • Page 207: Dynamics Of The Hydraulic Movements

    Operation Lifting Fork carriage sideshift  To move the fork carriage to the left: – Push the Joystick 4Plus (1) to the left (E). To move the fork carriage to the right: – Push the Joystick 4Plus (1) to the right (F). Movements of the lifting system and meanings of the pictograms  Lowering  Lifting...

  • Page 208: Selecting Load Programs 1 To 3

    When the operating device is released, the ● hydraulic movement decelerates very quick- The fork carriage quickly comes to a stand- still. Minimum dynamics The hydraulic movement accelerates very ● slowly when actuating the operating device.

  • Page 209: Fork Wear Protection (Variant)

    Operation Lifting – If the load programs are saved as a favour-  ite on a softkey, press the  softkey until the number of the desired load program is shown on the display. The number of dynamic bar segments shows the load dynamics of the selected load pro- gram.

  • Page 210: Changing The Fork Arms

    Operation Lifting protection (variant)" in the chapter entitled "Lift height-dependent assistance systems". The lift cylinders have in-built fixed stops to prevent the fork arms from hitting the ground. The lower stop makes inserting the forks into a pallet more comfortable. The driver cannot adjust the fork wear protec- tion manually.
  • Page 211 Operation Lifting NOTE It is recommended that a transport pallet is ● used to supporting the fork arms when they are being installed or removed. The pallet size depends on the size of fork arms in use. It should be large enough that the fork arms do not protrude after being placed on the pallet.

  • Page 212: Malfunctions During Lifting Mode

    Operation Lifting  DANGER There is a risk of fatal injury from a falling load or fork! – Tighten the locking screw (2) each time a fork is changed. – It is not permitted to drive or to transport loads without the locking screw in place. NOTE If the truck is equipped with the "load meas- urement"...

  • Page 213: Hydraulic Blocking Function

    Operation Lifting Load chains not under tension  DANGER Danger caused by a falling load! – Make sure that the chain(s) does (do) not become slack when lowering the load. Slack chains can, for instance, result from: Resting the fork carriage or the load on the ●...
  • Page 214 Operation Lifting NOTE Only the emergency steering function remains available.  200 55048015301 EN - 12/2023  -  07...

  • Page 215: Handling Loads

    Operation Handling loads Handling loads Safety regulations when handing  loads The safety regulations for handling loads are shown in the following sections.  DANGER There is a risk to life caused by falling loads or if parts of the truck are being lowered. –...
  • Page 216 Operation Handling loads  DANGER Risk of fatal injury from the truck losing stability! Never exceed the load capacity indicated on the capacity rating plate. This applies to compact and homogeneous loads. If these values are exceeded, the stability and rigidity of the fork arms and lift mast cannot be guaranteed.
  • Page 217 Operation Handling loads Basic capacity rating plate Basic capacity rating plate Sideshift "s" [mm] Side view of load and lifting accessories Designation of the lifting accessories (fork Load capacity [kg] arms or attachment) Top view of load and lifting accessories Lift height "h"...
  • Page 218 Operation Handling loads Typical application of a capacity rating plate 6219_003-356 The example values used here are marked in black. – To determine the actual load capacity, ob- serve the basic capacity rating plate on the truck.  204 55048015301 EN - 12/2023  -  07...
  • Page 219 Operation Handling loads Illustration of the typical application on the  truck The position numbers in the adjacent graphic correspond to the position numbers on the ba- sic capacity rating plate. 5880 mm Distance between the load centre of gravity and the fork back: 600 mm Permissible lift height: 5880 mm Weight of load to be lifted: 1000 kg The distance between the load centre of grav-...

  • Page 220: Picking Up Loads

    Operation Handling loads A large sideshift enables a strongly off-centre  load position. If the load is severely off-centre, the load capacity of the truck will be greatly reduced. XZP150 100x40x1200 Since non-integrated attachments can be re- h(mm) placed, multiple residual load capacity rating 6580 plates for attachments on one truck are pos- 5870...

  • Page 221: Danger Area

    Operation Handling loads sufficiently far apart and are positioned as far as possible under the load. If possible, the load should rest on the back of the fork. The load must not protrude too far over the fork tips, nor should the fork tips protrude too far out from the load.

  • Page 222: Transporting Pallets

    Operation Handling loads  DANGER Risk of injury! – Do not step on the fork.  DANGER Risk of injury! – Do not step under the raised forks.  DANGER People may be injured in the danger area of the truck! The danger area of the truck must be completely clear of all personnel, except the driver in his normal operating position.

  • Page 223: Transporting Suspended Loads

    Operation Handling loads Transporting suspended loads  Before transporting suspended loads, consult the national regulatory authorities (in Germa- ny, the employer's liability insurance associa- tions). National regulations may place restrictions on these operations, e.g. in Italy. – Contact the relevant authorities. –...

  • Page 224: Picking Up A Load

    Operation Handling loads shift or release unintentionally and cannot be damaged. When transporting suspended loads, suita- ● ble aids (e.g. guy wires or supporting poles) must be available so that accompanying persons can guide suspended loads and prevent the loads from swinging. Take particular care to ensure that there is ●...
  • Page 225 Operation Handling loads – Approach the rack carefully, brake gently  and stop just in front of the rack. – Position the forks.  – Set the lift mast to vertical. – Lift the fork carriage to the stacking height.  CAUTION Risk of component damage! When the fork is inserted into the rack, take care not...
  • Page 226 Operation Handling loads – Insert the fork as far under the load as pos-  sible. Stop the truck as soon as the fork back is resting on the load. The load centre of gravity must be midway between the fork arms.
  • Page 227 Operation Handling loads – Lower the load while maintaining ground  clearance. – Tilt the lift mast backwards.  The load can be transported. 55048015301 EN - 12/2023  -  07  213...

  • Page 228: Determining Visibility Conditions When Driving With A Load

    Operation Handling loads Determining visibility conditions when driving with a load 5510_003-010 Area that is not visible (max. 1085 mm) Load Load height (in driving position) Driver's eye level 4000 mm (distance to the front from the rear corner of the load when it is positioned on the fork carriage in the driving position) The driver's field of vision can be severely limited when driving with a larger load (Y) or...

  • Page 229: Transporting Loads

    Operation Handling loads Transporting loads  NOTE Observe the information in the chapter entitled "Safety regulations when driving".  DANGER The higher a load is lifted, the less stable it be- comes. The truck can tip over. The load can fall. There is an increased risk of accidents.

  • Page 230: Setting Down A Load

    Operation Handling loads – Never drive with a load protruding to the  side (e.g. with the sideshift)! Setting down a load  DANGER Risk of accident due to changed moment of tilt! The load centre of gravity and the moment of tilt move due to tilting the lift mast forwards with a raised load or due to the load slipping.
  • Page 231 Operation Handling loads – Drive up to the stack with the load lowered  in accordance with regulations. – Set the lift mast to vertical. – Lift the load to the stacking height. – Drive the truck towards the rack carefully. –...

  • Page 232: Driving On Ascending And Descending Gradients

    Operation Handling loads Driving on ascending and de-  scending gradients  DANGER Risk of fatal injury! Driving on ascending and descending gradients car- ries special dangers! – Always follow the instructions below. – On ascending and descending gradients, the load must be carried facing uphill. –...

  • Page 233: Driving Onto Lifts

    Operation Handling loads – Always place loads into stock and remove loads from stock on a horizontal plane. Driving onto lifts  The driver may only use this truck on lifts with a sufficient load capacity and for which the operating company has been granted authori- sation (refer to the section entitled "Definition of responsible persons").

  • Page 234: Driving On Loading Bridges

    Operation Handling loads – Park the truck securely in the lift and switch it off to prevent uncontrolled movements of the load or the truck. Driving on loading bridges   DANGER Risk of accident from the truck crashing! Steering movements can cause the rear of the truck to veer off the loading bridge towards the edge.
  • Page 235 Operation Handling loads – Drive slowly and carefully on the loading bridge. 55048015301 EN - 12/2023  -  07  221...

  • Page 236: Lift Height-Dependent Assistance Systems

    Operation Lift height-dependent assistance systems Lift height-dependent assistance systems Optical lift height measuring sys- tem (variant) Design and function  This truck can be fitted with an optical lift height measuring system as a variant. This system is a prerequisite for the assistance systems described in this chapter.
  • Page 237 Operation Lift height-dependent assistance systems Cleaning  It is recommended that the LED sensor glass (2) and the reflector (1) are checked before starting work and, if required, cleaned. The cleaning frequency depends on the appli- cation conditions of the truck. The quality of the light signal may also be reduced as a re- sult of heavy rain or fogging up of the sensor.
  • Page 238 Operation Lift height-dependent assistance systems  CAUTION Risk of damage to the LED lift height sensor through high-pressure cleaning! A high-pressure cleaner can damage the LED lift height sensor due to the penetration of water. This can result in incorrect measurements. –...
  • Page 239 Operation Lift height-dependent assistance systems Emergency operation in the event of malfunctions In the event of a malfunction in the height measurement system, the truck switches to emergency operation. In emergency operation, the assistance sys- tems listed below that are dependent on the lift height are not available: Lift height display ●...

  • Page 240: Lift Height Display (Variant)

    Operation Lift height-dependent assistance systems Lift height display (variant)  If the truck is equipped with the optical lift height measuring system, the current lift height (1) appears permanently in the display- operating unit. The lift height displayed corresponds to the 7,0°...

  • Page 241: Configuring Easy Target

    Operation Lift height-dependent assistance systems For the various operating devices for the hy- draulic functions, the approached lift heights are stored as follows. Multi-lever, mini-lever and Fingertip opera- ● tion: Function key Joystick 4Plus operation: ● Shift key "F" For harmonisation, the function key and the shift key "F"...
  • Page 242 Operation Lift height-dependent assistance systems A selection with the available areas of the  warehouse opens. – Press the appropriate softkey for the de- sired area of the warehouse to define a lift height. 6219_003-341_de A selection with the lift heights that can be ...
  • Page 243 Operation Lift height-dependent assistance systems In this menu, you can define the desired lift  height. – Enter the lift height using softkeys  0 to 9 – To , press the  button. save The menu closes. The selection with the lift heights that can be defined for this area of the Enter desired height warehouse opens.

  • Page 244: Operating Easy Target

    Operation Lift height-dependent assistance systems The stored lift height is displayed on the previ-  ously selected storage space. In this example, the lift height is 1.04 m. --,-- m 1,04 1,04 m 2,8° --,-- m --,-- m --,-- m 6219_003-345_de Operating easy Target ...
  • Page 245 Operation Lift height-dependent assistance systems Select the desired area of the warehouse ei-  ther in the function menu "Load ► easy Tar- get" or via the favourites. The adjacent exam- 12:19 ple shows the selection via a favourite (2). – Approach the selected lift height of the area 1,04 of the warehouse with the fork carriage.
  • Page 246 – Lower the fork carriage.  The fork carriage is automatically lowered only until the load has been set down. The fork carriage also stops if the operating device is still actuated. 1,15 1,00 The orange activation bar next to the "Place in 2,8°...
  • Page 247 2,8° -0,62 The fork carriage also stops if the operating device is still actuated. The orange activation bar next to the "Re- move from stock" symbol  indicates that the stock removal assistant is active.

  • Page 248: Intermediate Lift Cut-Out (Variant)

    Operation Lift height-dependent assistance systems Intermediate lift cut-out (variant)  This function interrupts the lifting process at a set lift height. The intermediate lift cut-out function is useful if the fork carriage is fre- quently lifted to a particular lift height. There are two options when buying the truck: When buying the truck, the lift heights at which the intermediate lift cut-out takes...
  • Page 249 Operation Lift height-dependent assistance systems NOTE The display always displays the next lift limit that is in the path of the current lifting move- ment. The next lift limit at which the function will intervene is highlighted in grey in the display.
  • Page 250 Operation Lift height-dependent assistance systems function intervenes again, the black symbol will reappear. Switching off the intermediate lift cut-out – Press the  button. The first menu level appears. – Press the  softkey. – Press the  softkey. The orange-coloured activation bar next to the softkey goes out.
  • Page 251 Operation Lift height-dependent assistance systems – Press the  softkey.  Lift cut-out Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en This menu offers three storage locations.  – To configure storage location 1, press Intermediate lift cut-out  softkey.

  • Page 252: Lift Transition Damping (Variant)

    Operation Lift height-dependent assistance systems In this menu, you can define the desired lift  height. – Enter the lift height using softkeys  0 to 9 Intermediate – To , press the  button. lift cut-out 1 save – To , press the scroll button activate The menu closes.

  • Page 253: Lift Mast End-Stop Damping (Variant)

    Operation Lift height-dependent assistance systems Lift mast end-stop damping (var- iant) This assistance system, in conjunction with the optical height measuring system, ensures that the fork carriage reaches the lifting stops gently. This prevents the lifting movement from stopping abruptly. If the truck is equipped with the "automatic mast vertical positioning"...
  • Page 254 Operation Lift height-dependent assistance systems NOTE The maximum lift height cannot be modified by the driver. It can be changed either by the authorised service centre or with the "Access authorisation for the fleet manager" via the display-operating unit. Configuration by the fleet manager –...
  • Page 255 Operation Lift height-dependent assistance systems – Press the  softkey.  End lift cut-out Intermediate lift cut-out 1 Intermediate lift cut-out 2 Intermediate lift cut-out 3 End lift cut-out Fleet manager 6219_003-315_en In this menu, you can define the desired lift ...

  • Page 256: Speed Reduction When The Fork Carriage Is Raised (Variant)

    Operation Lift height-dependent assistance systems – To deactivate the  End lift cut-out press the  softkey. End lift cut-out – Press the scroll button  Intermediate is deactivated. lift cut-out 1 End lift cut-out The orange activation bar goes out. Enter desired height 6,892 = Clear = Deactivate...
  • Page 257 Operation Lift height-dependent assistance systems – Press the   softkey.  Truck settings – Press the  Speed restriction for softkey. lift Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en 55048015301 EN - 12/2023  - ...
  • Page 258 Operation Lift height-dependent assistance systems – Press the  softkey.  Lift height Lift height Speed restriction Fleet manager 6219_003-321_en In this menu you can define the desired  height. Speed reduction when NOTE the fork carriage is raised » Lift height The assistance system intervenes automati- cally from 500 mm.
  • Page 259 Operation Lift height-dependent assistance systems – Press the   softkey.  Truck settings – Press the  Speed restriction for softkey. lift Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en 55048015301 EN - 12/2023  - ...
  • Page 260 Operation Lift height-dependent assistance systems – Press the softkey.  Speed restriction Lift height Speed restriction Fleet manager 6219_003-321_en In this menu you can define the maximum  speed. – Enter the speed using softkeys  0 to 9 Speed restriction –...

  • Page 261: Electrical Fork Wear Protection (Variant)

    Operation Lift height-dependent assistance systems Electrical fork wear protection  (variant) This assistance system, in conjunction with the optical height measuring system, ensures that the fork arms do not touch the ground. The correct height for inserting the forks in a pallet can also be configured.
  • Page 262 Operation Lift height-dependent assistance systems NOTE Alternatively, the authorised service centre can parametrise the "F" button to cancel the fork wear protection for the complete lowering of the fork. NOTE When you change fork arms, the fork wear protection must be zeroed. –...
  • Page 263 Operation Lift height-dependent assistance systems – Press the  Fork wear protection softkey. Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en In this menu you can define the desired ...

  • Page 264: Tilt Angle-Dependent Assistance Systems

    Operation Tilt angle-dependent assistance systems Tilt angle-dependent assistance systems Mast tilt angle display (variant)  Knowing the actual tilt angle of the lift mast makes it easier to place loads into stock and remove loads from stock. If the truck is equip- ped with the "mast tilt angle display"...
  • Page 265 Operation Tilt angle-dependent assistance systems positioning reduces wear on various compo- nents, thereby reducing repair costs. The "automatic mast vertical positioning" as- sistance system consists of the following indi- vidual functions: Display of the "Automatic mast vertical posi- ● tioning" feature Automatic startup of the "Automatic mast ●...

  • Page 266: Function Checking Of The Automatic Mast Vertical Positioning Function (Variant)

    Operation Tilt angle-dependent assistance systems Function checking of the auto- matic mast vertical positioning function (variant)  CAUTION Risk of damage to property due to the lift mast collid- ing with racks or other objects! – Before using the "automatic mast vertical position- ing"...
  • Page 267 Operation Tilt angle-dependent assistance systems – Drive the truck into an area that is to be used for placing loads into stock and re- moving loads from stock. Once the "automatic mast vertical positioning" assistance system has been calibrated, a pal- let can be stored horizontally in a rack when the truck is standing on a HGV ramp, for ex- ample.
  • Page 268 Operation Tilt angle-dependent assistance systems – Press the scroll keys    until the  Cal- menu appears. ibration – Press the  softkey. Calibration Maintenance interval Calibration Shock sensor Change password (access auth.) Relieve hydraulics Fleet manager 6219_003-277_en – Press the  softkey.

  • Page 269: Load-Dependant Assistance Systems

    Operation Load-dependant assistance systems Load-dependant assistance systems Overload detection (variant)  WARNING Risk of accident as a result of exceeding the permis- sible load capacity! This assistance system does not replace the driver's duty to observe the load capacity specified on the nameplate.
  • Page 270 Operation Load-dependant assistance systems Configuration by the fleet manager – Activate the "Access authorisation for the fleet manager". – Press the  button. – Press the  softkey. – Press the   softkey.  Truck settings – Press the soft-  Overload detection key.
  • Page 271 Operation Load-dependant assistance systems In this menu you can define the desired  weight. – Enter the weight using softkeys 0 to 9 Overload detection NOTE Only a lower value than the permissible load Enter desired weight capacity of the truck can be entered as an overload.
  • Page 272 Operation Load-dependant assistance systems Dynamic Load Control 1 regulates the lifting and tilting dynamics and the driving dynamics according to the following criteria: Lift height ● Load weight ● Load movements which could lead to critical conditions are slowed down if necessary. Dynamic Load Control 1 intervenes in the fol- lowing operating situations: With a telescopic lift mast:...
  • Page 273 Operation Load-dependant assistance systems  WARNING Risk of accident due to the slow response of the lifting system! If the lifting movements are configured to use low dynamics, the lifting system responds after a delay when the operating device is released, even in an emergency.
  • Page 274 Operation Load-dependant assistance systems NOTE When the fork carriage has been lowered be- low the lift heights mentioned above, the driver can deactivate the speed restriction again. Re- lease the accelerator pedal for a short period to do this. The bar display on the display of the display- ...

  • Page 275: Load Measurement (Variant)

    Operation Load-dependant assistance systems If a sensor belonging to Dynamic Load Con-  trol 2 fails, the level of intervention from the function is increased to a maximum. A cross appears instead of the bar. – If this display appears permanently, contact the authorised service centre.

  • Page 276: Calibrating The Load Measurement

    Operation Load-dependant assistance systems NOTE The load measurement must be calibrated in order to ensure accuracy at all times. The "access authorisation for the fleet manager" is required for the calibration. This access is required: After changing the fork arms, ●...
  • Page 277 Operation Load-dependant assistance systems – Activate the "Access authorisation for the fleet manager". – Press the   softkey.  Service – Press the scroll keys    until the  Cal- menu appears. ibration Maintenance interval Calibration Shock sensor Change password (access auth.) Relieve hydraulics Fleet manager 6219_003-277_en...

  • Page 278: Precision Load Measurement (Variant)

    Operation Load-dependant assistance systems – Press the  softkey.  Load measurement The wizard for calibrating the load measure- ment is started. Lift mast tilting – Follow the instructions on the display. – If the message Calibration Load measurement   appears, press the   softkey.
  • Page 279 Operation Load-dependant assistance systems – Press the  softkey (1).  0,70 --,-- 0,0° 6219_003-222   prompt is  Lower fork slightly displayed. – Lower the fork carriage. NOTE 0,70 Lower Slowly lowering the fork carriage increases 0,0° fork slightly the measurement accuracy in trucks with mul- ti-lever operation.

  • Page 280: Tare Function (Variant)

    Operation Load-dependant assistance systems If the calculation was successful, the meas-  ured weight of the load (1) is displayed. NOTE If the tare function was not active, the full 0,70 weight of the load being picked up is dis- 1,32 played.
  • Page 281 Operation Load-dependant assistance systems – Press the  softkey (1).  The activation bar next to the  symbol lights 0,70 --,-- 0,0° 6219_003-225   prompt is  Lower fork slightly displayed. – Lower the fork carriage. The value is calculated. The message Zero-  ...

  • Page 282: Total Load (Variant)

    Operation Load-dependant assistance systems Total load (variant)  Use the "total load" variant to calculate the total weight of multiple loads. The "total load" is an additional function of the "load meas- urement". It records the individual loads and stores up to three total loads. This allows, for example, three different con- tainers to be laden and their loading weight to be determined.
  • Page 283 Operation Load-dependant assistance systems The first menu level appears. – Press the  softkey. – Press the  softkey. A menu appears with three storage locations  for the total load. The total load is explained here using  0,00 – Press the  softkey.
  • Page 284 Operation Load-dependant assistance systems The message with the prompt  Lower fork   appears. slightly – Lower the fork carriage. The value is calculated. The Calc. ongo-   message appears. 0,70 Lower If the calculation was successful, the load is 0,0°...

  • Page 285: Zeroing The Assistance Systems

    Operation Zeroing the assistance systems Zeroing the assistance systems Zeroing process The following assistance systems sometimes require zeroing. Load measurement ● When changing fork arms or attachments Lift height display ● When replacing worn tyres For increasingly worn tyres / for new tyres Mast tilt angle display ●...
  • Page 286 Operation Zeroing the assistance systems – Press the softkey.  Zeroing Auxiliary hydraulics Change PIN codes Manage driver profiles On-board charger Zeroing Fleet manager 6219_003-323_en – Press the softkey for the assistance func-  tion for which the zeroing is to be per- formed, e.g.
  • Page 287 Operation Zeroing the assistance systems The instructions are shown in the display.  Here: Lower forks After the instructions have been followed, Load weight the messages Zeroing successful are displayed. Zeroing failed – If zeroing failed, try again. Lower forks –...

  • Page 288: Depressurising The Hydraulic System

    Operation Depressurising the hydraulic system Depressurising the hydraulic system Need to depressurise the hy- draulic system To enable additional hydraulic functions other  than the basic functions to be used, the truck has plug connectors (1) on the lift mast. Clamping and non-clamping attachments can be connected to these plug connectors.
  • Page 289 Operation Depressurising the hydraulic system authorised service centre can enable the func- tion for the driver. NOTE The wizard requires access authorisation for the fleet manager. Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied.
  • Page 290 Operation Depressurising the hydraulic system – Press the scroll keys    until the  menu appears. lieve hydraulics – Push the soft- Relieve hydraulics key. The following message appears:  Caution,   the lift mast may move! – To confirm, press the softkey.

  • Page 291: Depressurising The Hydraulic System Using Multi-Lever Operation

    Operation Depressurising the hydraulic system The following message appears:  Disen- gage all hydraulic axles, then   switch off the truck – Depressurise the hydraulics, see the rele- vant section for the respective operating de- vices.  WARNING The movements of the load lift system present a risk of crushing! During the depressurisation process, the fork car- riage or the lift mast can move slightly.

  • Page 292: Depressurising The Hydraulic System Using A Double Mini-Lever

    Operation Depressurising the hydraulic system The hydraulic circuits of the basic functions are now depressurised. Depressurising the hydraulic circuits for  the additional functions The additional features include features such as the sideshift and fork adjustment. Clamping attachments are also connected to these hy- draulic circuits.

  • Page 293: Depressurising The Hydraulic System Using The Double Mini-Lever And The 5Th Function

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the additional functions The additional features include features such as the sideshift and fork adjustment. Clamping attachments are also connected to these hy- draulic circuits. These functions are controlled via hydraulic circuits three and four.

  • Page 294: Depressurising The Hydraulic System Using A Triple Mini-Lever

    Operation Depressurising the hydraulic system – Push the cross lever (1) once in the direc- tion of the arrow until the end position is reached. The hydraulic circuit of the 5th hydraulic func- tion is depressurised. The plug connectors on the lift mast are depressurised. –...

  • Page 295: Depressurising The Hydraulic System Using The Triple Mini-Lever And The 5Th Function

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the additional functions The additional features include features such as the sideshift and fork adjustment. Clamping attachments are also connected to these hy- draulic circuits. These functions are controlled via hydraulic circuits three and four.

  • Page 296: Depressurising The Hydraulic System Using A Quadruple Mini-Lever

    Operation Depressurising the hydraulic system – Push the operating lever (1) once in the di- rection of the arrow until the end position is reached. The hydraulic circuit of the 5th hydraulic func- tion is depressurised. The plug connectors on the lift mast are depressurised. –...

  • Page 297: Depressurising The Hydraulic System Using The Quadruple Mini-Lever And The 5Th Function

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the additional functions The additional features include features such as the sideshift and fork adjustment. Clamping attachments are also connected to these hy- draulic circuits. These functions are controlled via hydraulic circuits three and four.

  • Page 298: Depressurising The Hydraulic System Using The Fingertip

    Operation Depressurising the hydraulic system – Push the operating lever (1) once in the di- rection of the arrow until the end position is reached. The hydraulic circuit of the 5th hydraulic func- tion is depressurised. The plug connectors on the lift mast are depressurised. –...

  • Page 299: Depressurising The Hydraulic System Using The Fingertip And The 5Th Function

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the additional functions The additional features include features such as the sideshift and fork adjustment. Clamping attachments are also connected to these hy- draulic circuits. These functions are controlled via hydraulic circuits three and four.

  • Page 300: Depressurising The Hydraulic System Using The Joystick 4Plus

    Operation Depressurising the hydraulic system The LED for the "5th function"   (3) lights up. – Push the operating levers (1) or (4) once in the direction of the arrow until the end position is reached. The hydraulic circuit of the 5th hydraulic func- tion is depressurised. The plug connectors on the lift mast are depressurised.

  • Page 301: Depressurising The Hydraulic System Using The Joystick 4Plus And The 5Th Function

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the additional functions The additional features include features such as the sideshift and fork adjustment. Clamping attachments are also connected to these hy- draulic circuits. These functions are controlled via hydraulic circuits three and four.

  • Page 302: Special Feature For Clamping Attachments

    Operation Depressurising the hydraulic system – Push the Joystick 4Plus (3) once in the di- rection of the arrow until the end position is reached. Push the horizontal rocker button (2) once in the direction of the arrow. The hydraulic circuit of the 5th hydraulic func- tion is depressurised.

  • Page 303: Attachments

    Fitting attachments If the truck is equipped with an integrated at- tachment (variant) at the factory, the specifica- tions in the STILL operating instructions for integrated attachments must be observed. If attachments are fitted at the place of use, the specifications in the operating instructions from the attachment manufacturer must be ob- served.
  • Page 304 Operation Attachments  WARNING Risk of accident due to incorrect labelling! The use of attachments can cause accidents if the labelling is incorrect or missing. If the truck is not fitted with an attachment-specific residual load capacity rating plate, and the operating devices are not marked with the relevant pictograms, the truck must not be used.
  • Page 305 Operation Attachments Plug connectors on the lift mast  – Before fitting the attachment, depressurise the hydraulic system; see the chapter enti- tled "Depressurising the hydraulic system".  CAUTION Risk of damage to components! Open connections on the plug connectors (1) can become dirty.

  • Page 306: General Instructions For Controlling Attachments

    Operation Attachments General instructions for control- ling attachments Attachments can be controlled via the first four hydraulic functions but also as a variant via the 5th function. The 5th function is activa- ted via a button on the operating device and by moving the operating device or additional push buttons.

  • Page 307: Attachment Example For The Connection Of The Auxiliary Hydraulics

    Operation Attachments NOTE If several hydraulic functions are used at the same time, these functions can influence each other. For example, if the fork carriage is raised and an attachment is operated at the same time, this may change the lifting speed or the operating speed of the attachment.
  • Page 308 Operation Attachments Attachment example for an attachment for ad-  justment of the fork arms Auxiliary hydraulics 1 Auxiliary hydraulics 2 Electrical connection for switch valve 1 (two switch valves are possible) If an attachment is connected to the auxiliary hydraulics 1 (1) and this attachment requires another function, this is referred to as the function of the auxiliary hydraulics 3.
  • Page 309 Operation Attachments NOTE The adjustment procedure requires access authorisation for the fleet manager. Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied. If the parking brake is released pre- maturely, the settings menu will close.
  • Page 310 Operation Attachments This menu indicates the supply flow.  The return flow is shown in a lighter colour. The currently set speed of the hydraulic ● Auxiliary hydraulics 2 pump is given in The currently set supply flow rate is given in ●...

  • Page 311: Clamp Locking Mechanism (Variant)

    Operation Attachments The return flow is displayed in addition to the  supply flow at full brightness. To adjust the revolution speed, press the  softkey. Auxiliary hydraulics 2 – To save the setting, press the  softkey. Forwards 3 900 1/min The settings are saved.
  • Page 312 Operation Attachments – See the section concerning the relevant op- erating device.  298 55048015301 EN - 12/2023  -  07...

  • Page 313: Controlling Attachments Using Multi-Lever Operation

    Operation Attachments Controlling attachments using  multi-lever operation In this version, the attachments (variant) are controlled using the operating levers (1, 3). The pictograms for the hydraulic func- tions (2, 4) are affixed to the operating levers. – Observe the pictograms (2) or (4). The pictograms are arranged according to the directions of movement of the operating lev- er (1) or (3).
  • Page 314 Operation Attachments NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary. Clamp locking mechanism NOTE For technical reasons, no clamp locking mech-...

  • Page 315: Controlling Attachments Using A Double Mini-Lever

    Operation Attachments Controlling attachments using a  double mini-lever In this version, the attachments (variant) are controlled using the "attachments" cross lev- er (1). The adhesive label bearing the picto- grams for the hydraulic functions (2) is affixed at the designated point. –...
  • Page 316 Operation Attachments NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary. Clamp locking mechanism ...

  • Page 317: Controlling Attachments Using The Double Mini-Lever And The 5Th Function

    Operation Attachments Controlling attachments using  the double mini-lever and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the "5th function". The function key for the "5th function" (3) and the cross lever (1) are used to control the "5th function".
  • Page 318 Operation Attachments Example using the pictograms for configura-  tion (1): If the "attachments" cross lever (1) is moved in the direction of the arrow (A), the fork is extended. If the function key for the "5th function" (3) is actuated and the "attachments" cross lever (1) is moved in the direction of the arrow (A), the fork arms open.

  • Page 319: Controlling Attachments Using A Triple Mini-Lever

    Operation Attachments Controlling attachments using a  triple mini-lever In this version, the attachments (variant) are controlled using the operating levers (1, 2). The adhesive label bearing the pictograms for the hydraulic functions (3) for the operating lever (2) and the adhesive label (4) for the op- erating lever (1) are affixed at the designated points.
  • Page 320 Operation Attachments Picto- Attachment function gram Tip shovel over Tip shovel back NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.

  • Page 321: Controlling Attachments Using The Triple Mini-Lever And The 5Th Function

    Operation Attachments Controlling attachments using  the triple mini-lever and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the "5th function". The function key for the "5th function" (2) and the operating lever (1) are used to control the "5th function".
  • Page 322 Operation Attachments Example using the pictograms for configura-  tion (1): If the operating lever (1) is moved in the direc- tion of the arrow (E), the sideshift moves to the left. If the function key for the "5th function" (2) is actuated and the operating lever (1) is moved in the direction of the arrow (E), the fork arms open.

  • Page 323: Controlling Attachments Using A Quadruple Mini-Lever

    Operation Attachments Controlling attachments using a  quadruple mini-lever In this version, the attachments (variant) are controlled using the operating levers (1, 2). The adhesive label bearing the pictograms for the hydraulic functions (3) for the operating lever (2) and the adhesive label (4) for the op- erating lever (1) are affixed at the designated points.
  • Page 324 Operation Attachments Picto- Attachment function gram Tip shovel over Tip shovel back NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.

  • Page 325: Controlling Attachments Using The Quadruple Mini-Lever And The 5Th Function

    Operation Attachments Controlling attachments using  the quadruple mini-lever and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the "5th function". The function key for the "5th function" (2) and the operating lever (1) are used to control the "5th function".

  • Page 326: Controlling Attachments Using The Fingertip

    Operation Attachments Picto- Attachment function gram Adjust fork arms: close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.
  • Page 327 Operation Attachments Picto- Attachment function gram Move the side shift frame or fork for- wards Move the side shift frame or fork backwards Move the sideshift to the left Move sideshift to the right Adjust fork arms: open Adjust fork arms: close Release load retainer Clamp load retainer Open clamps...

  • Page 328: Controlling Attachments Using The Fingertip And The 5Th Function

    Operation Attachments It is not necessary to release the clamp lock- ing mechanism in order to close the clamp. – To close the clamp, pull the operating lev- er (2) backwards. Controlling attachments using 1 2 3  the Fingertip and the 5th func- tion NOTE For technical reasons, clamping attachments...
  • Page 329 Operation Attachments Picto- Attachment function gram Move sideshift to the right Adjust fork arms: open Adjust fork arms: close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation...

  • Page 330: Controlling Attachments Using The Joystick 4Plus

    Operation Attachments Controlling attachments using  the Joystick 4Plus In this version, the attachments (variant) are controlled via the Joystick 4Plus (1) and the slider (4). The adhesive label bearing the pic- tograms for the hydraulic functions (2) for the Joystick 4Plus (1) and the adhesive label (3) for the slider (4) are affixed at the designated points.
  • Page 331 Operation Attachments Picto- Attachment function gram Rotate to the left Rotate to the right Tip shovel over Tip shovel back NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.

  • Page 332: Controlling Attachments Using The Joystick 4Plus And The 5Th Function

    Operation Attachments Controlling attachments using  the Joystick 4Plus and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the 5th function. Use shift key "F" (4) and the Joystick 4Plus (2) and the horizontal rocker button (1) to control the "5th function". The adhesive label bearing the pictograms for the hydraulic functions (3) for the Joy- stick 4Plus (2) and for the horizontal rocker 6219_003-166_V2...

  • Page 333: Picking Up A Load Using Attachments

    Operation Attachments The attachment moves accordingly in the di- rections (E) or (F) as shown in the pictogram. – Push the horizontal rocker button (1) in the direction (G) or (H). The attachment moves accordingly in the di- rections (G) or (H) as shown in the pictogram. –...

  • Page 334: Auxiliary Equipment

    Operation Auxiliary equipment Auxiliary equipment FleetManager (variant) FleetManager is an equipment variant and can be fitted to the truck in different versions. The description and operation information can be found in the separate operating instructions for the corresponding FleetManager versions. Shock recognition (variant) The shock recognition is an equipment var- iant of the FleetManager (variant) in which an...

  • Page 335: Actuating The Windscreen Wipers And Windscreen Washers (Variant)

    Operation Auxiliary equipment Actuating the windscreen wipers  and windscreen washers (var- iant) Pressing the softkey switches between the op- erating stages in the sequence shown below. Press softkey Operating stage   1st time 2nd time Interval 3rd time Hold (possible in all Washer operating stages) 6219_003-069_V2...

  • Page 336: Filling The Washer System

    Operation Auxiliary equipment Filling the washer system  – Open the filler cap (1) of the washer sys- tem. – Fill the washer reservoir with washer fluid as described in the "Maintenance data ta- ble".  CAUTION Damage due to the effects of frost! When water freezes, it expands.
  • Page 337 Operation Auxiliary equipment – Press the softkey   Truck settings – Press the  softkey.  Run-on time Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en 55048015301 EN - 12/2023  -  07  323...

  • Page 338: Clipboard (Variant)

    Operation Auxiliary equipment In this menu you can define the desired run-on  time. – Enter the run-on time using softkeys  0 to Run-on time – To , press the  button. save NOTE Enter run-on time If a run-on time has been activated, the truck Min.

  • Page 339: Rear Box

    Operation Auxiliary equipment Rear box   CAUTION Risk of damage to components. The rear box is made of plastic. It is sensitive to heat and scratches. – Do not store any hot, sharp, pointed or hazardous objects in the rear box, e.g. exposed blades. The rear box can accommodate bulky items that are difficult to store in the driver's cab, such as a charging cable or warning triangle.

  • Page 340: Display Messages

    The charge state of the battery is too low for truck use. - Charge the battery.     Special feature for STILL RXE: Battery empty The drive unit is limited to 5 km/h. The working hydraulics are limited in perform- ance.
  • Page 341 The battery can only absorb limited current from the energy recovery of the regenerative brake. As a result, the regenerative brake only offers limited deceleration. The service brake is still fully operational.   - Drive the truck carefully while actuating the Battery recovery low hydraulic functions.
  • Page 342 Operation Display messages Code Shown in display Cause/action The charging process has been automatically aborted due to the battery temperature being too high. This message about the on-board charger is triggered by different causes: The truck was heavily used before charging and the battery has become very hot.
  • Page 343 Operation Display messages Code Shown in display Cause/action The electrolyte circulation pump is not working. The charging process is continued without elec- trolyte circulation. Intermediate charging can Electrolyte circulation V7059   cause damage to the battery. not working - Cancel the charging process. - Contact your authorised service centre.
  • Page 344 - If the message continues to appear, please     contact the authorised service centre. Fault: Battery Special feature for STILL RXE: The truck will brake to a standstill. The drive unit is blocked. The working hydraulics are blocked. This message about the on-board charger is...
  • Page 345 Operation Display messages Code Shown in display Cause/action The parking brake cannot be applied due to a technical fault. - Apply the parking brake according to the sec- Parking brake cannot be   tion entitled "Malfunctions in the electric parking  ...
  • Page 346 Operation Display messages Code Shown in display Cause/action The charging button on the truck connector for the charging cable has been held down too A5902 long. Re-insert charging V6954   - Pull the truck connector out and re-insert it plug after approx.
  • Page 347 Operation Display messages Code Shown in display Cause/action There is a fault with the charging program. The On-board charger power V7001 charging process is performed with reduced reduction - service re- V7062 power.   quired - Contact your authorised service centre. This message is not displayed during normal  ...
  • Page 348 Operation Display messages Code Shown in display Cause/action If the battery is charged after blocking sprint mode or a normal temperature is reached, this     Enable sprint mode message appears. Sprint mode can be used again once the truck has been restarted. If the battery experiences under voltage or too high a temperature, this message appears.

  • Page 349: Messages About The Truck

    – Switch the truck off and on again. – If the message still appears, please contact the authorised service centre. The messages are sorted in ascending order according to their code:...
  • Page 350 Operation Display messages Code Shown on display Description/possible solution A6510   Electric parking brake detects fatal fault Fault: Parking brake A6511   Brake cannot release Fault: Parking brake A6512   Brake cannot apply Fault: Parking brake None   General fault Error  336 55048015301 EN - 12/2023  - ...

  • Page 351: Procedure In Emergencies

    Operation Procedure in emergencies Procedure in emergencies Emergency shutdown   WARNING No electric braking assistance is available when the emergency off switch is actuated! Actuating the emergency off switch (1) will discon- nect the drives from the power supply. Disconnecting the battery male connector (2) discon- nects the entire truck from the power supply.

  • Page 352: Procedure If Truck Tips Over

    Operation Procedure in emergencies No power steering effect; the steering ● forces are increased by the remaining emergency steering function The "Curve Speed Control" system (auto- ● matic reduction in truck speed when corner- ing) does not function. Brake the truck using the service brake.
  • Page 353 Operation Procedure in emergencies As the truck can only be moved to a limited extent, this poses a risk of accident. These are the possible controls for the drive direction: The drive direction switch on the operating ● device for the hydraulic functions The drive direction selection lever on the ●...

  • Page 354: Emergency Lowering

    Operation Procedure in emergencies Emergency lowering If the hydraulic controller fails whilst a load is raised, emergency lowering can be performed. An emergency lowering screw designed for this purpose is located on the valve block.  DANGER There is a risk to life from falling loads or from truck components being low- ered.
  • Page 355 Operation Procedure in emergencies – Loosen the three screws (3) on the panel-  ling (2) and remove the panelling (2). 5510_003-024 – Remove the three screws on the valve  block cover and remove the valve block cover. NOTE Depending on the operating device for the hy- draulic functions, the truck is equipped with different valve blocks.
  • Page 356 Operation Procedure in emergencies – Using the hexagon socket wrench, turn the  emergency lowering screw (4) a maximum of 1.5 revolutions to loosen it. Proportional-valve technology For mini-lever, Fingertip and Joy- stick 4Plus operation Mechanical valve technology In multi-lever operation  WARNING The load is lowered! Unscrewing the emergency lowering screw regulates the lowering speed.

  • Page 357: Towing

    Operation Procedure in emergencies Towing Safety information  DANGER The truck could drive into the towing vehicle when the towing vehicle brakes. Risk of accident! For safety reasons, a person authorised to drive must steer and brake the truck. It must be ensured that either the service brake or the parking brake is working.
  • Page 358 Operation Procedure in emergencies  WARNING Risk of accident due to unguided truck! If the towed truck is not steered, the truck may veer out in an uncontrolled manner. The truck being towed must also be steered and braked by a driver. The driver of the truck being towed must sit in the driver's seat and fasten the seat belt before towing.
  • Page 359 Operation Procedure in emergencies – Screw the eye bolt (1) to the rear weight to  the stop. – Check the pulling and braking forces of the towing vehicle. – With the help of a guide, move the tow- ing vehicle behind the counterweight of the truck.

  • Page 360: Access To The Battery Compartment And Battery Male Connector

    Operation Access to the battery compartment and battery male connector Access to the battery compartment and battery male connector Opening and closing the battery door (variant) Opening – Press the battery door release button (1)  and open the battery door forwards. The battery door is held in the open position by a spring mechanism and an end position latch.

  • Page 361: Opening And Closing The Battery Hood

    Operation Access to the battery compartment and battery male connector  WARNING Risk of accident due to the battery door opening! An unlocked battery door may open if the truck de- celerates sharply. If the battery door opens while driving, there is risk of damage from a collision. –...
  • Page 362 Operation Access to the battery compartment and battery male connector  WARNING Risk of burns due to hot components! Components become very hot during use. – Do not touch components except as described in this paragraph. – Wear safety gloves. – Position the driver's seat as far back as it can go.
  • Page 363 Operation Access to the battery compartment and battery male connector  CAUTION Risk of crushing the battery cable possi- ble. When closing the battery hood, the bat- tery cable could become trapped. There is risk of short circuit due to the battery cable being crushed or sheared off! –...

  • Page 364: Connecting The Battery Male Connector

    Operation Access to the battery compartment and battery male connector Connecting the battery male connector – Open the battery hood.  CAUTION Risk of damage to the battery male connector! If the battery male connector is connected while the key switch is switched on (under load), a jump spark will be produced.

  • Page 365: Disconnecting The Battery Male Connector

    Operation Access to the battery compartment and battery male connector – Before closing the battery hood, place the  battery cable (8) under the bracket (7). – Close the battery hood. Batteriekabelführung Disconnecting the battery male connector  CAUTION Risk of damage to the battery male connector! If the battery male connector is disconnected while the key switch is switched on (under load), a jump spark will be produced.
  • Page 366 Operation Access to the battery compartment and battery male connector – Pull the battery cable (8) out from under the  bracket (7) and expose it. Batteriekabelführung – Disconnect the battery male connector (4)  from the plug connection by pulling in the direction of the arrow.

  • Page 367: Quick Charge Access

    Operation Quick charge access Quick charge access Quick charge access (variant) The charging quick-access (variant) is an ad- ditional charger socket behind a lid on the left- hand side panel. This charger socket enables charging of lead-acid batteries and lithium-ion batteries without having to open the battery hood.
  • Page 368 Operation Quick charge access Safety information  DANGER Risk of explosion due to flammable gases! During charging, the lead-acid batteries release a mixture of oxygen and hydro- gen (oxyhydrogen gas). This gas mixture is explosive and must not be ignited. There must be no flammable materi- als or spark-forming operating materials within 2 m of either the truck when it is parked for charging or the battery charg-...
  • Page 369 Operation Quick charge access  DANGER Risk of fire due to overheated connec- tion assembly! Do not pull out the mains plug under load as this will result in excessive wear and pose a fire hazard. – If the mains plug needs be pulled out before the end of the charging process, cancel the charging process at the battery charger first.
  • Page 370 Operation Quick charge access General NOTE To ensure maximum battery life, always charge lead-acid batteries fully. Observe the maximum charging current limitation for exter- nal battery chargers for quick charge access. For intermediate charging during work breaks, use an air agitation pump (variant). Lithium-ion batteries may be charged intermediately as often as required with no restriction to the bat- tery life.
  • Page 371 Operation Quick charge access Battery charging takes place. The display-op- erating unit shows nothing. – When the charging process is complete, disconnect the charging cable from the charging quick-access (1). 2. Lead-acid battery with truck switched The parking brake is applied automatically or a message appears in the display of the dis- play-operating unit prompting the driver to ap- ply the parking brake.
  • Page 372 Operation Quick charge access – When the charging process is complete, disconnect the charging cable from the charging quick-access (1). Charging state display in the display-op- erating unit for lithium-ion batteries When charging lithium-ion batteries, the  charging state display (3) appears in the dis- play-operating unit.

  • Page 373: Handling The Lead-Acid Battery

    Operation Handling the lead-acid battery Handling the lead-acid battery Safety regulations for handling the battery – Follow the national statutory provisions for the country of use when setting up and op- erating battery charging stations.  CAUTION Risk of component damage! Incorrect connection or incorrect opera- tion of the charging station or battery charger may result in damage to compo-...
  • Page 374 Operation Handling the lead-acid battery The battery must only be replaced in accord- ance with the directions in these operating in- structions. – When charging and maintaining the battery, observe the manufacturer's maintenance in- structions for the battery and the battery charger.
  • Page 375 Operation Handling the lead-acid battery Lifting accessories  DANGER Risk of accident! The battery may fall from the lifting accessory. The lifting accessory may tip over or be damaged. If this happens, there is a risk to life. The battery must be removed only when the truck is on level, even ground with sufficient load capacity.
  • Page 376 Risk of accident as a result of failure of the energy supply! If batteries are used that are not approved by STILL, an accident may occur due to failure of the energy supply. The cable cross-section area of the battery cables must be at least 95 mm...

  • Page 377: Maintaining The Battery

    Operation Handling the lead-acid battery Maintaining the battery  DANGER Danger to life and limb! – Observe the instructions in the chapter entitled "Safety regulations when handling the battery".  WARNING Battery acid is toxic and corrosive! – Observe the safety regulations in the chapter enti- tled "Battery acid".

  • Page 378: Checking The Battery Condition, Acid Level And Acid Density

    Operation Handling the lead-acid battery Checking the battery condition, acid level and acid density  WARNING The electrolyte (diluted sulphuric acid) is poisonous and corrosive! – Observe safety regulations for han- dling battery acid; see the chapter en- titled "Battery acid". –...

  • Page 379: Checking The Battery Charge State

    Operation Handling the lead-acid battery After charging, the acid density must be be- tween 1.28 and 1.33 kg/l. For a discharged battery, the acid density must be no lower than 1.14 kg/l. NOTE The required acid density after charging may vary depending on the manufacturer. Observe the operating instructions of the battery used.
  • Page 380 Operation Handling the lead-acid battery Meaning of the colours in the display  NOTE An abrupt change in the charging state display does not indicate a malfunction. The battery charge indicator allows the driver to detect any preliminary damage to the battery. If abrupt changes in the display begin to occur more frequently, have the battery and the charging process checked by the authorised service...

  • Page 381: Charging The Lead-Acid Battery

    Operation Handling the lead-acid battery Charging the lead-acid battery  DANGER Explosive gases are generated during charging. The oxyhydrogen gas produced during charging is usually odourless. Older bat- teries may have a sulphurous odour due to contamination. – Ensure that work areas are adequate- ly ventilated.
  • Page 382 Arrange for the authorised service centre to repair the connection assembly. NOTE STILL recommends that you always use com- ponents (plug and socket) from the same manufacturer for the connection assembly be- tween the battery charger and the battery. The...
  • Page 383 Operation Handling the lead-acid battery – Park the truck securely. – Ensure that work areas are adequately ven- tilated. – Make sure that the external ventilation gaps on the truck are unobstructed and are not blocked. – Fully open any protective structures (e.g. fabric-covered cab).
  • Page 384 Operation Handling the lead-acid battery – Disconnect the battery male connector (1)  by pulling the handle. – Connect the battery male connector (1) to the plug on the battery charger. 5510_003-028 – Ensure that the battery cable (2) does not  lie over the catch bolt (3) of the battery hood when charging.

  • Page 385: Equalising Charging To Preserve The Battery Capacity

    Operation Handling the lead-acid battery – Insert the battery male connector (4) fully  into the plug connection on the truck.  CAUTION There is a risk of short circuit if the ca- bles are damaged. Do not crush the battery cable when closing the battery hood.
  • Page 386 Operation Handling the lead-acid battery NOTE Depending on the battery charger used, the equalising charge may not begin until 24 hours have elapsed. A period when no shifts are running, such as the weekend, is therefore ideal for performing the equalising charge. –...

  • Page 387: Battery Maintenance Indicator For Lead-Acid Batteries (Variant)

    Operation Handling the lead-acid battery – Insert the battery male connector (4) fully  into the plug connection on the truck.  CAUTION There is a risk of short circuit if cables are damaged. Do not crush the battery cable when closing the battery hood.

  • Page 388: Handling The Gel Battery

    Operation Handling the gel battery If the acid level is too low, the message  Checking the battery acid level appears on the display of the display-operat- ing unit. 0,09  CAUTION 3,3° Check Risk of damage to the lead-acid battery! battery acid level If the acid level in one or more battery cells is too...
  • Page 389 Operation Handling the gel battery While a conventional lead-acid battery can use 80% of the energy contained in the bat- tery, the gel battery uses only 60%. On the other hand, a gel battery is safe from deep discharge due to its design (according to DIN 43 539, Part 5).
  • Page 390 Operation Handling the gel battery Maintenance personnel Only personnel trained for this purpose may: Charge the battery ● Replace the battery ● This work must be carried out according to the instructions of the battery manufacturer and of the charger manufacturer. –...
  • Page 391 Operation Handling the gel battery Damage to cables and battery male connector  CAUTION There is a risk of short circuit if the cables are dam- aged. Do not crush the battery cable when closing the bat- tery door. – Check the battery cable for damage. –...
  • Page 392 Operation Handling the gel battery – Start the battery charger. NOTE Observe the information in the operating in- structions for the battery and the battery charger. After charging  CAUTION Risk of damage to components! – Switch off the battery charger before you discon- nect the charging cable.

  • Page 393: Handling The Lithium-Ion Battery

    Operation Handling the lithium-ion battery Handling the lithium-ion battery Safety regulations for handling the lithium-ion battery First-aid measures  WARNING Risk of injury! Escaping gases can lead to breathing difficulties. Course of action required if gases or liquids escape – Immediately ventilate the area or go out into the fresh air;...
  • Page 394 Operation Handling the lithium-ion battery  WARNING Risk of crushing/shearing! The battery is very heavy. There is a risk of serious injury if any parts of the body are caught under the battery. If parts of the body are wedged between the battery door and the edge of the chassis when the battery door is closed, this could lead to injuries.
  • Page 395 Operation Handling the lithium-ion battery – Observe the information provided by the battery manufacturer regarding the proce- dure in the event of a fire. Battery weight and dimensions  DANGER Risk of tipping due to change in battery weight! The battery weight and dimensions affect the stability of the truck.

  • Page 396: Illustration Of A Lithium-Ion Battery

    Operation Handling the lithium-ion battery Illustration of a lithium-ion battery Example image Technology compartment Safety valve Battery male connector Diagnostic connector Lifting eyes Display  WARNING Risk of accident due to weakened lifting eyes. If bent lifting eyes are straightened, they lose their rigidity.

  • Page 397: Regulations For Storing Lithium-Ion Batteries

    Operation Handling the lithium-ion battery Regulations for storing lithium- ion batteries NOTE Lithium-ion batteries are classified as danger- ous goods according to class 9. The following recommendations apply: Wherever possible, store batteries at ● ground level so that they cannot be dam- aged by falling Store the batteries in a segregated area ●...
  • Page 398 Operation Handling the lithium-ion battery – Store in a way that protects the batteries against short circuits – Store batteries at a safe distance from flam- mable materials – Do not store batteries together with metallic objects – Store lithium-ion batteries separately from other types of batteries (no mixed storage) –...

  • Page 399: Checking The Battery Charge State

    Operation Handling the lithium-ion battery Checking the battery charge state The charge state of the lithium-ion battery can be read on the display-operating unit of the truck and on the lithium-ion battery display. Reading on the display-operating unit  – Apply the parking brake. –...
  • Page 400 Operation Handling the lithium-ion battery The truck can no longer be moved. A charge state of > 20% to 30% is indicated ● by yellow bars. A charge state of > 30% to 100% is indica- ● ted by green bars When charging, the charge state LEDs (3) light up green as a chase light.

  • Page 401: Charging The Lithium-Ion Battery

    Operation Handling the lithium-ion battery – If the charge state drops below 15%, drive to the charging station and charge the bat- tery.  WARNING There is no electric brake assistance when the bat- tery is switched off! The drives are de-energised when the battery is au- tomatically switched off.
  • Page 402 Operation Handling the lithium-ion battery  CAUTION Risk of damage to components. Damage and contamination of the battery male con- nector or the plug on the battery charger can lead to premature wear of the counterpart. – Before each charging process, check both sides of the connection assembly between the battery charger and the battery for damage and contami- nation.
  • Page 403 Operation Handling the lithium-ion battery – Gently press in the lid (2) and release it.  The lid (2) is partially opened by a spring. – Then open the lid (2) completely by hand and hold it. The lid (2) is secured against unintentional opening by a spring.
  • Page 404 Operation Handling the lithium-ion battery Charging state display on the display- operating unit for lithium-ion batteries When charging lithium-ion batteries, the  charging state display (3) appears in the dis- play-operating unit. If the charging state display (3) does not ap- 10:48 pear, there is an error.

  • Page 405: Battery Heating System

    If the truck is parked at temperatures below 5°C, connect a battery charger if possible. NOTE When purchasing a used STILL RXE, have the authorised service centre check to see whether the truck is equipped with a battery heating system. Only if there is a battery heat- er is it possible to park the truck at tempera- tures below 5°C for an extended period.

  • Page 406: Replacing And Transporting The Battery

    Using his/her access authorisation, the fleet manager can set the new battery capacity and the new battery type in the display-operating unit. – Use only lithium-ion batteries that have been approved by STILL for use with this truck.  392 55048015301 EN - 12/2023  -  07...

  • Page 407: Replacing The Battery Using An External Roller Channel (Variant)

    Operation Replacing and transporting the battery Setting the new battery capacity and the new battery type – Stop the truck. – Apply the parking brake. – Press the  button. – Press the  softkey. The first menu level appears. – Activate the "Access authorisation for the fleet manager".
  • Page 408 Operation Replacing and transporting the battery  WARNING Risk of accident due to overloading of the means of transport used! The load capacity of the means of transport used must at least match the weight of the battery and the weight of the changing bridge. –...
  • Page 409 Operation Replacing and transporting the battery Battery type RXE 10 (5510) RXE 13 (5513) RXE 15 (5515) RXE 16C (5516) 7 PZS 8 PZS – Park the truck securely on a level and hori- zontal surface and switch off the truck. Removing the battery – Open the battery hood and the battery door.  CAUTION Potential for damage to the battery male connector! If the battery male connector is disconnected while...
  • Page 410 Operation Replacing and transporting the battery – Read off the battery type on the battery's  nameplate and set the indexing bolt (2) to this battery type. – To do this, loosen the indexing bolt with an open-ended spanner (16 mm AF), slide it into the correct battery type in the slotted piece and tighten the indexing bolt again.
  • Page 411 Operation Replacing and transporting the battery The external roller channel is placed correctly.  – Loosen the screw (3) and remove the bat- tery lock (4). – Move the battery out of the battery compart- ment and close the battery safety catch (1) in the opposite direction.

  • Page 412: Replacing The Battery With A C Hook (Variant)

    Operation Replacing and transporting the battery – Place the battery cable (8) under the brack-  et (7). – Close the battery hood and the battery door. Batteriekabelführung Replacing the battery with a C hook (variant)  DANGER Risk of fatal injury caused by failure of the lifting equipment! –...
  • Page 413 Operation Replacing and transporting the battery Removing the battery – Open the battery hood (1) and the battery  door (3).  CAUTION Risk of damage to the battery male connector! If the battery male connector is disconnected while the key switch is switched on (under load), a jump spark will be produced.
  • Page 414 Operation Replacing and transporting the battery – Pull the battery cable (8) out from under the  bracket (7) and expose it. – Disconnect the battery male connector and place it on the battery. – Place the C hook above the battery (5). –...

  • Page 415: Special Notes For Installing The Lithium-Ion Battery

    Operation Replacing and transporting the battery – Place the battery cable (8) under the brack-  et (7). – Close the battery hood and the battery door. Batteriekabelführung Special notes for installing the  lithium-ion battery With the exception of the following special notes, lithium-ion batteries are replaced in the same way as lead-acid batteries.

  • Page 416: Transporting The Battery By Crane

    Operation Replacing and transporting the battery Transporting the battery by  crane  DANGER Risk of fatal injury from falling load! – Never walk or stand underneath sus- pended loads. – Park the truck at a sufficient distance from obstacles to prevent damage to the truck when lifting the battery using the crane.

  • Page 417: Li-Ion Ready

    STILL lithium-ion batteries are exclusive STILL innovations and are matched to the ap- plication and the truck in question. This means that STILL lithium-ion batteries meet the high- est demands and achieve a particularly high quality and safety standard.
  • Page 418 If the truck is Li-Ion ready, the truck has an ac-  cess point at the side or the rear for charging the lithium-ion battery. Only approved STILL lithium-ion batteries may be used to retrofit a lithium-ion battery.  CAUTION Component damage due to excessive charging cur- rents.

  • Page 419: Cleaning The Truck

    Operation Cleaning the truck Cleaning the truck Cleaning the truck  WARNING Risk of injury from falling off the truck! When climbing onto the truck, there is a risk of getting stuck or slipping and falling. Use suitable equipment to reach higher points on the truck.
  • Page 420 Operation Cleaning the truck  CAUTION Excessive water pressure or water and steam that are too hot can damage truck components. – Strictly adhere to the following steps.  CAUTION Possible component damage due to compressed air. – If components are cleaned with compressed air, the air must have a maximum pressure of 0.15 bar.

  • Page 421: Cleaning The Electrical System

    Operation Cleaning the truck – Clean plastics only with cleaning materials intended for plastics. – Clean the truck exterior using water-soluble cleaning materials and water. Cleaning with a water jet, a sponge or a cloth is recom- mended. – Clean all accessible areas. –...

  • Page 422: Cleaning Load Chains

    Operation Cleaning the truck Cleaning load chains   WARNING Risk of accident! Load chains are safety elements. The use of cold/chemical cleaners or fluids that are corrosive or contain acid or chlorine can damage the chains and is forbidden! – Observe the manufacturer's guidelines for working with cleaning materials.
  • Page 423 Operation Cleaning the truck – Thoroughly dry the truck after wet cleaning, e.g. using compressed air. – Apply a thin layer of oil or grease to all uncoated moving parts. – Grease the truck. – Lubricate the joints and controls. –...

  • Page 424: Transporting The Truck

    Operation Transporting the truck Transporting the truck Transport  CAUTION Risk of material damage from overloading! If the truck is driven onto a means of transport, the load capacity of the means of transport, HGV ramps and loading bridges must be greater than the total actual weight of the truck.

  • Page 425: Wedging The Wheels

    Operation Transporting the truck  DANGER Risk of accident from the truck crashing! Steering movements can cause the rear of the truck to veer off the loading bridge towards the edge. This may cause the truck to crash. – Before driving across a loading bridge, ensure that the loading bridge is properly attached and secured.

  • Page 426: Lashing Down

    Operation Transporting the truck – Disconnect the battery male connector. Lashing down  CAUTION Abrasive lashing straps can rub against the surface of the truck and cause damage. – Position slip-resistant pads underneath the lifting points (3) (e.g. rubber mats or foam). –...

  • Page 427: Crane Loading

    Operation Transporting the truck Crane loading Crane loading is only intended for transport- ing the complete truck, including the lift mast, for its initial commissioning. This may be per- formed only by the authorised service centre with the harnesses expressly provided and ap- proved for this purpose.

  • Page 428: Decommissioning

    Operation Decommissioning Decommissioning Decommissioning and storing the truck  CAUTION Damage to components due to incorrect storage! Improper storage or decommissioning for a period of more than two months can result in corrosion damage to the truck. If the truck is parked in an ambient temperature of below -10°C for an extended period, the batteries will cool down.
  • Page 429 Operation Decommissioning  CAUTION Potential for damage to the battery male connector! If the battery male connector is disconnected while the truck is switched on (under load), an electric arc will be produced. This can lead to erosion of the contacts, which considerably shortens the service life of the contacts.

  • Page 430: Use After Storage Or Decommissioning

    Operation Decommissioning service centre to find out about additional courses of action. Use after storage or decommis- sioning If the truck has been decommissioned for lon- ger than six months it must be checked care- fully before being used again. As with the an- nual safety inspection, this check must also include all safety-related aspects of the truck.

  • Page 431: Maintenance

    Maintenance...

  • Page 432: Safety Regulations For Maintenance

    Maintenance Safety regulations for maintenance Safety regulations for maintenance General information To prevent accidents during maintenance and repair work, all necessary safety measures must be taken, e.g.: – Apply the parking brake. – Turn off the key switch and remove the key. –...

  • Page 433: Safety Devices

    Maintenance Safety regulations for maintenance Rings, metal bracelets etc. must be removed before working on electric components. To prevent damage to electronic systems with electronic components, such as an electronic driving regulator or lift control, these compo- nents must be removed from the truck prior to the start of electric welding.

  • Page 434: Working At The Front Of The Truck

    Maintenance Safety regulations for maintenance Working at the front of the truck  DANGER Risk of accident due to an unsecured lift mast. If the lift mast or fork carriage is raised, no work may be performed on the lift mast or at the front of the truck unless the appropriate safety measures are put in place.

  • Page 435: General Maintenance Information

    Maintenance General maintenance information General maintenance infor- mation Personnel qualifications Only qualified and authorised personnel are allowed to perform maintenance work. Regu- lar safety checks and checks after unusual incidents must be performed by a competent person. The competent person must conduct their evaluation and assessment from a safety standpoint, unaffected by operational and eco- nomic conditions.
  • Page 436 Maintenance General maintenance information below. This ensures that the truck remains ready for operation and provides optimal per- formance and service life. It is also a precondi- tion for any warranty claims. Maintenance timeframe If maintenance is needed, the message  ...

  • Page 437: Setting Up And Adjusting The Due Date Counter For Maintenance And Safety Checks

    Maintenance General maintenance information The first menu level appears. – Activate the "Access authorisation for the fleet manager". – Press the   softkey. Service The "Service menu" opens on the display. – Press the Maintenance interval softkey. This menu shows the operating hours remain- ing until the next scheduled maintenance in- terval or the latest date of the next scheduled maintenance interval.
  • Page 438 Maintenance General maintenance information Setup and adjustment by the fleet man- ager For the fleet manager, due date counters are also defined for the following checks: Regular testing of the truck for electric ● trucks and IC trucks Battery testing for electric trucks ●...
  • Page 439 Maintenance General maintenance information menu  Safety check – Press the scroll button to activate the input. Safety check – Enter the desired date using softkeys 0 to – To , press the  button. save Enter date Due date counter for individual mainte- 30 .
  • Page 440 Maintenance General maintenance information  426 55048015301 EN - 12/2023  -  07...

  • Page 441: Maintenance - 1000 Hours/Annually

    Maintenance General maintenance information Maintenance - 1000 hours/annually   At operating hours Carried 1000   2000   4000   5000   7000   8000   10000   11000   13000   14000         Chassis, bodywork and fittings  ...
  • Page 442 Maintenance General maintenance information   At operating hours Carried 1000   2000   4000   5000   7000   8000   10000   11000   13000   14000         Perform a brake test.     Electrical system  ...
  • Page 443 Maintenance General maintenance information   At operating hours Carried 1000   2000   4000   5000   7000   8000   10000   11000   13000   14000         Check the fork arms for wear and deformation.  ...
  • Page 444 Maintenance General maintenance information  430 55048015301 EN - 12/2023  -  07...

  • Page 445: Maintenance - 3000 Hours/Every Two Years

    Maintenance General maintenance information Maintenance - 3000 hours/every two years Carried At operating hours   3000   6000   9000   12000   15000         Note     Perform all 1000-hour maintenance work.     Brake    ...

  • Page 446: Lubrication Plan

    Maintenance General maintenance information Lubrication plan 5510_003-053 Code Lubrication point One lubricating nipple on the steering turntable Sliding surfaces on the lift mast Load chains The respective lubricant specification can be found in the "Maintenance data table" section below, under this Code. This lubrication plan describes the series-production truck with standard equipment.

  • Page 447: Maintenance Data Table

    Maintenance General maintenance information Maintenance data table General lubrication points Code Unit Operating materials Specification Dimension   Lubrication High-pressure ID no. 0147873 As required grease Battery Code Unit Operating materials Specification Dimension   System filling Distilled water   As required Insulation resistance   DIN 43539 For further informa- VDE 0510...
  • Page 448 Maintenance General maintenance information Tyres Code Unit Operating materials Specifications Dimension   Superelastic tyres Wear limit   To wear mark Solid rubber tyres Wear limit   To wear mark   Pneumatic tyres Minimum tread depth   Air pressure: see in- formation on truck Min.

  • Page 449: Providing Access To Maintenance Points

    Maintenance Providing access to maintenance points Providing access to maintenance points Removing/installing the valve cover Removal NOTE The hexagon socket wrench that is used to remove the valve cover is also used for emer- gency lowering. – Apply the parking brake and switch off the truck.

  • Page 450: Removing And Installing The Bottom Plate For Single Pedal Operation

    Maintenance Providing access to maintenance points – Remove the three screws on the valve  block cover and remove the valve block cover. Installation – Fit the valve block cover, screw in and tight- en the screws. – Fit the panelling (2) and screw it on with three screws (3).
  • Page 451 Maintenance Providing access to maintenance points Removing the left-hand bottom plate  NOTE The left-hand bottom plate must be removed before the right-hand bottom plate can be re- moved. The left-hand bottom plate (1) has a gap for gripping with the fingers. The recess is located underneath the rubber covering (4).

  • Page 452: Removing And Installing The Bottom Plate For Dual Pedal Operation (Variant)

    Maintenance Providing access to maintenance points Removing and installing the bot- tom plate for dual pedal opera- tion (variant)  WARNING Risk of crushing when closing the bot- tom plate! When the bottom plate is closed, there must be no parts of the body between the bottom plate and the edge of the chassis.
  • Page 453 Maintenance Providing access to maintenance points Removing the left-hand bottom plate – Lift up the bottom plate (4). – Disconnect the connecting plug from the ac- celerator. – Remove the bottom plate (4). Installing the left-hand bottom plate – Fit the bottom plate (4). –...

  • Page 454: Preserving Operational Readiness

    Maintenance Preserving operational readiness Preserving operational readiness Lubricating joints and controls  – Oil or grease bearings and joints according to the "maintenance data table". Driver's seat guide ● Battery hood hinges ● Battery door hinges ● Actuating rod (1) for valves (with multi-lever ●...

  • Page 455: Maintaining The Seat Belt

    Maintenance Preserving operational readiness NOTE The interval for greasing is influenced signifi- cantly by the application conditions and the environmental conditions affecting the truck. Visual inspections and function checking of the hood lock must be carried out as required and after every 1000 hours. Grease all moving parts of the hood lock as necessary.
  • Page 456 Maintenance Preserving operational readiness Checking the seat belt – Pull out the belt (3) completely and check  for wear. The belt must not be frayed or cut. The stitch- ing must not be loose. – Check whether the belt is dirty. –...

  • Page 457: Checking The Driver's Seat

    – If you wish to use a type of tyre or tyre manufac- turer that has not been approved by STILL, obtain approval from STILL prior to use. – Do not change rim parts and do not mix rim parts from different manufacturers.

  • Page 458: Check The Brake Fluid Level

    Maintenance Preserving operational readiness Checking the condition and wear of the  tyres – Remove any foreign bodies embedded in the tyres (1). The level of wear exhibited by tyres on the same axle must be approximately the same. Superelastic tyres and solid rubber tyres can be worn down to the "60J wear limit" (2).

  • Page 459: Checking The Battery

    Maintenance Preserving operational readiness  WARNING Risk of accident as a result of a low brake fluid level! If there is a low brake fluid level, there may be a leakage. – Never top up brake fluid, contact an authorised service centre. –...

  • Page 460: Adjusting The Warning Zone Light

    Maintenance Preserving operational readiness Adjusting the warning zone light  – Switch on the truck. – Make sure that the parking brake is applied. – Loosen the nuts (2) to adjust each head- light. – Adjust the headlight (1). The distance from the light bar to the truck must be between 70...75 cm.
  • Page 461 Maintenance Preserving operational readiness NOTE To check the hydraulic oil level, the hydraulic system must be bled. If there is a noticeable juddering in the hydraulic movements, contact the authorised service centre. – Drive the truck onto a level and horizontal surface.

  • Page 462: Checking The Hydraulic System For Leak Tightness

    Maintenance Preserving operational readiness – > 2410...≤ 2610 > 2060...≤ 2610 23.7 – – > 2610...≤ 3260 27.4 NOTE – If necessary, pour hydraulic oil of the cor- rect specification as specified in the "main- tenance data table" into the filler neck. ENVIRONMENT NOTE Carefully collect any spilled oil and dispose of it in an environmentally friendly manner and...

  • Page 463: Lubricating The Lift Mast And Roller Track

    Maintenance Preserving operational readiness Replace hose lines if they display the following abnormalities: Outer layer has been damaged, or is brittle ● or cracked Leakages ● Deformation (e.g. with blisters or kinks) ● A fitting has come loose ● A fitting is badly damaged or corroded ●...
  • Page 464 Maintenance Preserving operational readiness  450 55048015301 EN - 12/2023  -  07...

  • Page 465: 1000-Hour Maintenance/Annual Maintenance

    Maintenance 1000-hour maintenance/annual maintenance 1000-hour maintenance/annual maintenance Other work that must be carried – Perform all tasks required to maintain full operability; see the chapter entitled "Re- maining ready for operation". Checking the lift cylinders and  connections for leaks  WARNING Risk of injury Observe safety regulations for working on the lift...

  • Page 466: Checking The Fork Arms

    Maintenance 1000-hour maintenance/annual maintenance Checking the fork arms  – Check the fork arms (1) for any visible de- formation. Wear must not amount to more than 10% of the original thickness.  CAUTION Risk of component damage! Always replace worn fork arms in pairs. –...

  • Page 467: Technical Data

    Technical data...

  • Page 468: Dimensions

    Technical data Dimensions Dimensions β α 5510_003-046 Seat is adjustable ± 90 mm Fork spacing is adjustable  454 55048015301 EN - 12/2023  -  07...
  • Page 469 Technical data Dimensions NOTE Measurements h and b are cus- tomised and can be taken from the order con- firmation. 55048015301 EN - 12/2023  -  07  455...

  • Page 470: Vdi Datasheet

    Different tyres, lift masts, additional units etc. can produce different values. Key data Model RXE-10 RXE-13 RXE-15 RXE-16C Type number 5510 5513 5515 5516 STILL STILL STILL STILL Manufacturer GmbH GmbH GmbH GmbH Drive Electric Electric Electric Electric...
  • Page 471 Technical data VDI datasheet Model RXE-10 RXE-13 RXE-15 RXE-16C Type number 5510 5513 5515 5516 Number of front wheels   (x = driven) Number of rear wheels   (x = driven) Track width, front (mm) Basic dimensions Model RXE-10 RXE-13 RXE-15 RXE-16C Type number...
  • Page 472 Technical data VDI datasheet Model RXE-10 RXE-13 RXE-15 RXE-16C Type number 5510 5513 5515 5516 Turning radius (mm) 1229 1391 1445 1480 Smallest pivot point distance (mm) Performance data Model RXE-10 RXE-13 RXE-15 RXE-16C Type number 5510 5513 5515 5516 Driving speed with load km/h Driving speed without load...
  • Page 473 Technical data VDI datasheet  WARNING To use the truck safely – with or without a load – the maximum ascending or descending gradient per- mitted for travel is 15%. – If you have any questions, contact your authorised service centre. Electric motor Model RXE-10...

  • Page 474: Ergonomic Dimensions

    Technical data Ergonomic dimensions Ergonomic dimensions  40 mm  WARNING Danger of impact injuries to the head! If the head of the operator is located too close to the underside of the roof, the suspension of the driver's seat or an accident may cause the head to strike the overhead guard.
  • Page 475 Technical data Battery specifications for lithium-ion batteries Battery specifications for lithium-ion batteries NOTE Lithium-ion batteries for trucks with quick charge access are delivered from the factory with shorter battery cables for design reasons. Please note the following: These lithium-ion batteries may be used on- ●...
  • Page 476 Technical data Battery specifications for lithium-ion batteries Li-Ion 24 V 14,2 (BG 22.2) Type Battery 2252 2253 Tray 3104 3104 Nominal voltage [V] Nominal capacity [Ah] Nominal energy [kWh] 14.2 14.2 Length [mm] Width [mm] Height [mm] Battery heating system Used in type number RXE-10C (5510) RXE-10C (5510) Ballast weight...
  • Page 477 Technical data Eco-design requirements for electric motors and variable speed drives Li-Ion 24 V 14,2 (BG 22.2) Type Battery 2250 2251 Tray 3107 3107 Nominal voltage [V] Nominal capacity [Ah] Nominal energy [kWh] 10.6 10.6 Length [mm] Width [mm] Height [mm] Battery heating system RXE-13 (5513), RXE-15 RXE-13 (5513), RXE-15 Used in type number...
  • Page 478 Technical data Eco-design requirements for electric motors and variable speed drives  464 55048015301 EN - 12/2023  -  07...
  • Page 479 Index   Safety information....289 Special risks..... 39 Access authorisation for the fleet manag- Automatic mast vertical positioning er.
  • Page 480 Condition of the roadways... . 150 STILL Classic....144 Conformity marking....
  • Page 481 Index   Renaming..... . 129 Selecting..... . . 126 Filling the washer system.
  • Page 482 Tilting the lift mast....192 STILL SafetyLight®....Still Safety Light® 4Plus... 141 Labelling points.
  • Page 483 Index   First-aid measures....Tyres......434 Illustration.
  • Page 484 Index   Quadruple mini-lever....Quick charge access....353 Triple mini-lever....Operating instructions Rear box.
  • Page 485 Index   Working on the electrical equipment. Working on the hydraulic equipment. Tare function..... . Safety regulations for working on the lift Technical data mast.
  • Page 486 Speed restriction....168 Working on the hydraulic equipment..418 STILL SafetyLight® and STILL Safety- Working spotlight for reverse travel Light 4Plus®....141 Switching on and off.
  • Page 488 STILL GmbH 55048015301 EN - 12/2023  -  07...

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